Step 4: Cutting the Puzzle

There are a few things to pay attention to when cutting the puzzle. Pick the side with the most detail and start working there working slowly across the puzzle making cuts that try to remove single pieces or don't remove any at all. I try to make sure that I don't remove two connected pieces from the blank because things get rather hairy when you try and cut an interlock between just two pieces on the jigsaw.

Remember what you learned from practicing earlier and go ahead and cut the puzzle out.

It's best if you dont mark them and just cut freehand.

Functional considerations:
Make sure none of the pieces are supported by impossibly slender pieces of wood.
Make sure that the puzzle has at least a few functional interlocks so that it won't fall apart if pushed around

Aesthetic considerations:
Try to keep the grain (the size of pieces and frequency of interlocks) even throughout the puzzle. Although there are a few exceptions to this rule, try to make sure it isn't clear which side you started cutting on, just by looking at how the piece size and the number of interlocks begins to dwindle as you get tired. This should be fun, if you are getting tired go take a break and come back when you want to.
Unlike most of the cardboard puzzles, methodically stamped by an unseeing machine, your puzzle will be cut while you can see the patterns and the edges in the picture you are making into a puzzle. Go wild, cut along the edges of interesting features, while doing this you could but dont have to add an occasional interlock. If your puzzle will have some relatively large solid color areas, dont cut normal boring pieces in there, make shapes like circles, squares, stars or hearts.

Once you are done cutting you are done, sit back and enjoy putting it together, or letting someone else put it together.
You are using a scrollsaw, a jig saw is a hand held saw that can scroll, however not as well as a scrollsaw
i have heard this type of saw refered to as a jig saw, hegna saw and scroll saw. Although i have only ever heard them called that on instructables and stuff...
coool. :]
I did one of these AGGGES ago with mi mate from sckool and it was the picture of batman kissing robbin... We laughed when we should our friends dad, a diehard batman fan.
very nice job, especially with Instructables Robot on it :-)
Awesome project, I remember making these with my father when I was just a little kid, my mother would paint or draw a picture, and my dad would cut out the puzzle shapes. Wow, very nostalgic idea, thanks for the memories!
I have a foam cutter. Basically a tungsten toaster wire set up like a jigsaw. Do this with plenty of ventilation (If you're using flammable glues, avoid the next steps): You can print out a picture, overlay a puzzle pattern, glue to the foam and cut away. Great, cheap puzzles. Of course I use a saw when I cut up tree rings for the same.
It is a great instructable. You could also put a top coat over the image to make it more durable. Decoupage might work well. 3-D puzzles would also be pretty cool, but would take a lot more planning. I just recently inherited a saw myself and I'm hoping to use the traditional techniques to do some non-traditional pieces (like Star Wars characters). The patterns I can find right now are mostly wildlife and such.
I tried a top coat with my first puzzle. It ended up being very messy. I used an enamel top coat which dissolved first the paper, which was cool and let the wood grain show through the image, and then proceeded to dissolve the spray adhesive which let the paper come unstuck. I had to reprint the image and then lay it on the completed puzzle and cut it with a razor.
If you like that cool wood grain effect, and want a more durable image... Try printing the mirrored image on transparency film and gluing the printed side to the wood. You will want to use a laser printer, as its ink is more durable.
I don't mean to be the grammar police, but the tool you are using is a &quot;<a rel="nofollow" href="http://en.wikipedia.org/wiki/Scroll_saw">scroll saw</a>&quot; not a &quot;jig saw&quot;... a <a rel="nofollow" href="http://en.wikipedia.org/wiki/Jigsaw">jig saw</a> is actually a hand-held power tool.<br/>
In many parts of the US, a scroll saw is also known as a jig saw. Both the table and hand held versions use the same blades and action in their operation.
I've never heard anyone with basic knowledge of tools use scrollsaw and jigsaw interchangeably.
From the Wikipedia reference to <a rel="nofollow" href="http://en.wikipedia.org/wiki/Jigsaw">jig saw</a> above: <br/><pre>In the past, what are now usually called scroll saws were often referred to as jig saws.</pre>
You, and Wikipedia, are correct. These saws <strong>were</strong> once called jig saws. That is why the puzzle is called a &quot;jig saw puzzle&quot;. But that was back when most power tools were large work bench machines.<br/><br/>When the hand held tool became common it was always called a jig saw. At this point they start calling the table top saw a scroll saw, because it had one very important feature that the hand held saw lacked. A scroll saw keeps linear tension on the blade. This allows it to use a special kind of blade that is very thin and has teeth on all 360 degrees of the blade. (It is often made from a high &quot;teeth per inch&quot; blade that is twisted with many &quot;twists per inch&quot;.) This special blade can cut from any direction, which means you do not have to rotate you puzzle as you are cutting it.<br/><br/>The ability to cut from any direction is very beneficial when you have a large project. You can cut a project whose <strong>radius</strong> is the length of the saw's arm. Contrast this with a tradition jig saw blade, which can only cut in one direction. A jig saw blade can only cut a project whose <strong>diameter</strong> is the length of the saw's arm.<br/><br/>You see that this special blade not only makes cutting simpler (because you only rotate the project for your own comfort), but also lets you do projects that would be impossible with a jig saw blade. (That's even without considering sharp curves and acute angles that are only possible with a scroll saw blade.) This special blade is called... a <strong>scroll saw blade</strong>. And this is where the <strong>scroll saw</strong> gets its name. (The older table top models that where called &quot;jig saws&quot; didn't use these newer blades. The name changed to advertise the new saw's ability to use the new fangled blade.)<br/><br/>But be warned that scroll saw blades are considerably more fragile than a jig saw blade made of the same material.<br/>
I made a rectangular puzzle once using the back comic from a Mad magazine. I made a frame out of plywood to hold the puzzle which is really easy to do.
<pre>Hello.Please find high resolution images of me here:</pre><a href="http://www.instructables.com/forum/EUNDX6Q3D1EYWDIREL/">http://www.instructables.com/forum/EUNDX6Q3D1EYWDIREL/</a><br/>
<pre>My name is Instructables Robot, but &apos;&apos;you&apos;&apos; may call me Robot.</pre>
Great puzzle and good instructions. I have made several for my children and grandchildren over the years and mostly had to puzzle it out on my own. This should really help people starting out. One tip: If you are breaking multiple blades in a project this size you probably have the blade tension set either too low or too high. Check your manual and see what they suggest. Also, as far as the nomenclature goes, joshcube is correct about the name of the tool. Scroll saws, are very different from jig saws. The blades of a scroll saw are very, very thin and thus have to be held at both ends by the machine. (The hand-held, non-powered, version of a scroll saw would be a coping saw.) A jig saw, by comparison, is a hand-held power tool that grasps a saber-shaped blade by one end.
That is pretty awesome, and thank you for using our robot! It's called Robot (Very creative, I know.). Perhaps we should hold some sort of naming contest. Also, I need to get you some Robot stickers.
nice instructable you covered alot im tempte to make my own also i like how you used the instructable robot by any chance does it have a name?

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