Puzzles are great! They make you think outside the box. I came across the idea of this puzzle online. Not knowing how it was put together or solved, I started thinking how I would make it. The original puzzle that I saw, only had one locking bar on each side. Thinking that I could make it better, I challenged myself to figure out a way to take this simple puzzle to the next level.

If you know how the original puzzle is constructed and solved, please let me know if their solution is any different than mine.

Step 1: Tools and Materials


  • Saw
  • Flat tooth saw blade/dado stack on a table saw or router (to make rabbets)
  • Drill
  • Drill bits of varying size
  • Countersink bit
  • Angle grinder or hacksaw
  • Sander


  • 2 - 1 1/2 inch x 3/4 inch x approx. 4 inch
  • 2 - 1 1/2 inch x 3/4 inch x approx. 3 inch
  • 1/4 inch x 1 inch long Steel Rod
  • 6mm x 3mm Neodymium Magnet
  • Spark Plug - Any inexpensive spark plug will work
  • Wire "bars" - I visited my local thrift store and picked up this dish dryer for a couple bucks. A cookie rack or other type of rack would work just as well.
  • Two part Epoxy
  • Lacquer
<p>Very clever Puzzle, what program did you use for the wire flame animated drawing?</p>
<p>I actually drew modeled it up quickly in Solidworks then took successive screenshots of each feature being added. I dumped those screenshots into Photoshop to make the gif. Hope that helps! </p>
<p>Yes it does help, Thank you.</p>
<p>That would be a good instructable in it self :)</p>
<p>it took me a while to understand where the hole for the latching rod was drilled. It would have been good to add that to the drawing in step 6. I think I have figured it out.</p>
<p>Sorry for the confusion. I had this originally but thought that it made the diagram more confusing than to leave it out. </p>
<p>Wonderful! I would love to see some woodworking like this that could be done with hand tools. I am a vet and part of my right hand is mechanical. Gave all my power tool away. Only use hand tools now. Just finished making 7 foot rack to display wife's quilts. Only took 3 days.</p>
<p>'surviver' &gt;&gt; Thank you for your service!</p>
<p>I would suggest doing all the finishing before assembly. Sand first, then tape all the glue faces, rather the the fussy taping of the bars.</p>
<p>That is definitely an option, however I decided that this was the best option for me to ensure that all the faces were 100% flat with each other as well as all my holes lined up correctly. If you make one with your technique I would love to see the result! </p>
Great DIY puzzle! The choice to use a sparkplug is interesting and walnut was a great choice! I've never utilized a Rabbet joint before, so how would you cut that? Also, would it be safe to make the walls a little thinner than 3/4&quot;?
<p>I made my rabbets by taking multiple passes on the table saw with a flat tooth blade. If you don't have a table saw, you can also make them with a flat router bit on a router table. </p><p>You could possibly make the boards thinner, but not too much thinner. The side with the latching rod needs to be thick enough to allow the bars to slide into it allowing clearance for the other side. </p>

About This Instructable




Bio: My name is Troy. I'm a Mechatronics graduate studying Mechanical Engineering. I love making things and doing anything outdoors (especially SCUBA diving). I am ... More »
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