Precision Puzzlemaking Primer -- Volume 1

Step 17 Closing remarks and safety considerations

After building and trying to assemble a few of the more elaborate puzzles that I presented in the following steps, you may be wishing that you had been more careful during the ripping and/or crosscutting steps. If you find that your blocks aren't lining up properly then that usually indicates that something earlier on wasn't calibrated right. Sometimes sandpaper can help coerce poorly cut or glued blocks into their proper positions, but usually you'd be better off just cutting new ones. Be patient with this process -- don't expect to get it exactly right the first time through.

There has been a tremendous amount of material covered in this primer -- following along with me from start to finish will most certainly take up months of your free time. Do not attempt this project if you do not know how to safely operate woodworking machinery. These guidelines are intended for woodworkers with a moderate degree of prior experience, and who already know how to properly operate and adjust a table saw.

Be safety conscious when running long batches of repetitive tasks. Keep mentally aware of the running saw blade at all times! When working with this sled, keep both hands firmly braced on the sled plates or cross supports, and keep your body braced against the saw. Never put your fingers unnecessarily near the path of the saw blade. Use toggle clamps whenever possible. Never put your thumbs anywhere between the two center carriage bolts in the back cross support! Paint it bright red if necessary for you to remember this. Never reach your hands over or across the blade or behind the sled when the blade is running. Be sure that the miter grooves on the table saw surface remain free from debris which might jam up the movement of the sled. Wear safety glasses at all times. Be smart about what you do in the workshop. Have a plan for what to do if something goes wrong.

(BTW, that's not my hand... I just googled "cut finger image")