Last week I posted a dowel puzzle that contained 8 segments. To my surprise, it turned out to very challenging for my coworkers because there was only a 25% completion/success rate. The typical time before someone asked for a hammer to make the pieces fit was about 5 minutes.

This week, I’ve upped the challenge with a larger, 16 segment version. As you will see, symmetry doesn’t help out this time.

Step 1: Tools/Materials

Tools:

Saw (table, miter, band or hand)
Sander
Wood Clamps

Materials:

Wood - 6.5” x 4” x .5” thick
Wood - 1.5” x 24" x .5” thick
Dowel – 1” diameter x 48” Long
Glue

Step 2: Build

You will build your puzzle to this drawing.

Step 3: Box

You will build the box to this drawing.

Step 4: Base

Cut 1/2" thick wood to 4" x 6.5". Since the dowels are 1" in diameter, you might want to add a small amount to the 4" dimension.

Step 5: Sides

Cut the sides as shown. If you grew the base, grow the 4" dimension on the side as well.

Step 6: Assemble Base

Use glue to attach the sides to the base. Use wood clamps to apply pressure. I filled in a few small gaps with glue & saw dust at this point.

Step 7: Segments

The first 8 segments are cut with a 60 degree angle. Make two for each piece that has a (x2) note. I used a combination of a miter saw and band saw. For safety reasons, I used the band saw for the smaller pieces.

Step 8: Segments

The straight pieces are simple to cut. The green piece with angles on both sides took a little time since you will need to make the cuts parallel. Take your time and this shouldn't be an issue.