It all started in our class “It’s time to make it” guided by Mayur Bhalavi. Our objective was to democratize the process of making. We had to choose anything which is very much attached to ourselves and do it on our own.

I decided to make Jenga blocks and then I thought why just a Jenga it was not challenging. Then my childhood memory stuck an idea in my mind. I was very much attached to building blocks in my childhood. Why not make blocks which could also be used as building blocks. I started ideating and finally decided to make three holes on top and three extrusions on both sides. Here it is. Learn how to make the Jenga which is not just a Jenga.

Supplies

Pinewood blocks (4:25x30mm 2m length)
Bamboo dowels (10:4-5mm preferred)
White adhesive
Linseed Oil (Optional)

Tools:

Table Saw Thickness Planer (Optional)
Table Sander / Sand Paper
Drilling Machine
Hammer
Cutter
Scale, Marker, Caliper, Protracter

Step 1: Design

Each block is 15x25x75 mm standard dimension and holes at the specified dimension.

Step 2: Cutting the Sticks

Use table saw to cut the wooden sticks in 15x25 cross-section. I used thickness planer to get accurate cuts on all the sides. To make the game more challenging reduce the thickness of 1/3rd of the sticks you have to 14.5mm.

Step 3: Making the Blocks

Cut the wooden bars to equal lengths of 75mm each. Totally you need 54 blocks to play but make few more extra in case you may lose accuracy or the block may fail.

Roughly sand the edges of all the blocks to remove irregularities

Step 4: Drilling the Holes

Use a drill bit which is slightly thinner than your bamboo sticks so that bamboo gets attached to it while inserting. To drill first mark a point on sides as shown in the design, hold it below the drill bit and make a fixture to make it easy to drill all the remaining blocks. Again to drill on the top sides of the block, repeat the same procedure by marking on the top.

Drill size: 3-4 mm on the smaller side of the block & through holes on the larger side of the block.

Step 5: Attaching the Bamboo Sticks

Cut the bamboo sticks into small pieces of around 20-25mm. Slightly longer sticks make it easier to hold while hammering. Sand one edge of the stick, apply white glue on one side and hammer it into one of the hole. Use two blocks of wood and place the block other side and hammer a stick into that as shown in the video.

Step 6: Cut Off the Extra Stick

Cut off the extra stick using a cutter or with a sander if you have for a smooth and flat finish. While cutting it with the sander, use half cut block below stick to avoid breakage.

Step 7: Finishing the Blocks

Using finer sandpaper sand the blocks to get a smooth finish on all the sides.

Step 8: Apply Linseed Oil

To avoid scratches and changes in humidity apply Linseed oil on all the surfaces and let it dry in the sunlight for a while and now your blocks are ready.