How to Make a 3-D lion puzzle

 Hi out there, hope you are feeling well and ready to begin a new project. Today we are going to make a beautiful puzzle that is also decor for around the house.

  

Equipment and supplies

Nice piece of wood approx 1/2" thick

Proxxon mini scroll saw

Proxxon mini table saw

Proxxon mini belt sander

Proxxon OZI/E delta sander

carbon paper, pencil 

sealer of your choice

wood glue

   Got my inspiration from someone who had done a horse.  Not wanting to copy exactly, I made a lion.   I drew out my own design.  This was my first drawing but I did not take into account that the pieces are up in the air and so they better lock well with each other.  I did sneak in a rock to help support him also.

Using carbon paper, I transferred my design onto my wood piece. I had a nice piece of black walnut to work with.

 

The next step is to cut out the design.  Proxxon mini scroll saw does the work easily.  First cut out the design outline as one piece.

Next, carefully go in and cut apart the puzzle pieces.   This is delicate so I used the slow speed on my Proxxon mini scroll saw.  This helps me make the delicate cuts.  Keep in mind they need to interlock well.

Now, we sand, sand, sand.  I want to take off the edges, so they are rounded and smooth.  This will show off the puzzle effect I am going for.   I used the Proxxon OZI/E delta sander and the Proxxon cordless mini belt sander to do the job.  

To make a base to stabilize the lion, I cut a piece of wood approx 2" x 5" and I made a slot for the lion's back foot and rock piece to fit in.  This just adds stability.  I am going to use the Proxxon mini table saw for this.

I set the saw blade at about 1/4" height and I set the fence about 1" from the saw blade and run the base piece over the blade.  It is not wide enough to insert the lion piece yet so I move it just the tiniest bit either way and run those boards through it again. I do this several times until my piece will fit snuggly into the slot  Then I glued the bottom piece in

I used some polycrylic to seal the wood which also gave it a slightly darker tone that I really liked.

Uh oh.... then I ran into some trouble.  My puzzle would not stand.  The small little forefoot of the lion kept slipping so....Using the Proxxon professional rotary tool. I drilled a hole right through his foot and into the stand and inserted a small skewer stick.  That held it.  Yay.   

Then the rest of the lion could be assembled and if left unbumped would stay together.    psssst.... the polycrylic also helped by filling in the kerf lines for a snugger fit.  

All done.   See how I changed the skewer stick into a magic wand with a little paint and a sparkly bead on the end.  He is a magic lion.  He stands 8" tall.   He has a nice shine and he is sooo smooth to touch.  It's a tactile thing.  And, the more he is played with the smoother he will become.  

Thanks for visiting.   And thank you  Proxxon.  Your tools are awesome and make making things a joy.

Till next time, play safe,

Carol