Build Your Own Jigsaw Puzzle

Easy to make and fun to play with, this puzzle will become a true keepsake. Use a favourite photograph, children's school art, numbers or maps. Using half-inch pine for the backing material ensures no sharp edges. Remember both sides are available if you wish to make a double-sided puzzle. Resize the pattern to fit your puzzle, or design your own shapes.

What you'll need
Tools

• plastic straight edge or scraper 1630-266
• scroll saw 1345-048
• sander 1262-369

Material

• Weldbond adhesive (or equivalent) 2020-413
• fine sandpaper 1233-793
• rubber cement 5738-650
• backing material (¾" pine)
• photograph or artwork of your choice

Step-by-step

1. Cut backing material to the size of the photograph or artwork to be used. If you are using the puzzle pattern provided, your photograph may be enlarged on a photocopier, which is what we did. However, it is also easy and fun to design your own pattern.
2. Seal the surface of the backing material with Weldbond adhesive, smoothing over the entire surface with a straight edge. Allow it to dry thoroughly. The milky appearance will become clear when dry.
3. Apply a second coat of Weldbond, in a similar manner, to the surface of the backing material and immediately place the photograph onto the wet surface. Use a straight edge to carefully remove any bubbles or ripples etc., taking care not to damage the surface of the photograph. Allow it to dry completely.
4. Apply a coat of Weldbond to the surface of the photograph. Be sure to apply the coat as evenly and smoothly as possible. Again, the milky appearance will become clear when the glue dries. When dry, a second surface coat may be applied to give a harder, more durable surface.
5. Apply a thin coat of rubber cement to the backside of the puzzle pattern (NOT the picture surface), and quickly place it over the photograph surface. This will hold the pattern in place while you cut out the jigsaw puzzle and protect the surface of the puzzle during that process. It will peel off once the puzzle has been cut out.
6. Using a scroll saw, cut out the puzzle pieces. Tip: Practice using the scroll saw on a piece of scrap wood. Cut all horizontals, then all verticals.
7. Carefully peel off the paper pattern from each puzzle piece, gently removing any residual rubber cement.