Scroll saw puzzle for grandson

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Project by DaleMaley posted 08-11-2019 09:47 PM 725 views 0 times favorited 6 comments Add to Favorites Watch

I have made about 6 scroll saw puzzles for the grandkids….....they love to play with them.

On this one, I thought I would try something different. I wanted to include my grandson’s name on this puzzle.

My process was:

1. Cut pine blank

2. Paint blank white on both sides

Note: Use oven at 120F to speed up paint drying process

3. Apply blue masking tape to top of blank

4. Glue full scale pattern of puzzle from Sketchup onto blue tape using white Elmer’s glue

5. Scroll saw the puzzle

6. remove paper pattern and blue tape

7. Using carbon paper, and a Sketchup print-out of the letters, trace them through the carbon paper

8. Paint letters 1st time, bake in oven for 10 minutes

9. Give 2nd coat of paint to letters and bake

10. Apply blue masking tape as guide for top and bottom horizontal 1/4” wide bars

11. Paint 2 coats of paint for the 2 bars

12. Remove blue masking tape

13. Paint back grey

If I do another one like this, I would change my background color from white to maybe grey or dark yellow…...I just don’t care for the white.

I would also paint the 2 horizontal stripes before I scroll sawed the puzzle. I did them last, and had some paint bleed under the blue masking tape at the saw joints.

But, I bet my grandson and his sister will still love playing with it !

If you are interested in all the details of this project…..........see my web site.


-- Dale, Illinois,

6 comments so far

View DaleMaley's profile


593 posts in 3521 days

#1 posted 08-11-2019 09:49 PM

In 3/4” thick pine, a #4 scroll saw blade gives just the right fit to the puzzle pieces.

A #3 gives too tight of fit….......and a #5 gives too sloppy of a fit.

Hardwoods may require something other than a #4 for the optimum fit of the pieces.

-- Dale, Illinois,

View doubleDD's profile


10801 posts in 3328 days

#2 posted 08-11-2019 11:56 PM

Excellent job on the puzzle. The grand kids should learn to spell their name easier.

-- Dave, Downers Grove, Il. -------- When you run out of ideas, start building your dreams.

View Ivan's profile


17050 posts in 4153 days

#3 posted 08-13-2019 05:59 AM

Outstanding not ordinary design of those puzzles.

-- Ivan, Croatia, Wooddicted

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