Chocolate Box Puzzle




Introduction: Chocolate Box Puzzle

About: I like to design and build random things.

This is a fun and easy project to make. The goal is to fit the blocks of "chocolate" into the box. Compared to my other puzzles, I would rate the difficulty of this puzzle as a 2 out 5.

Below is a quick video of the solution.

I felt like this version was pretty easy to make but if you are not up to it, feel to purchase a similar version from online.

Step 1: Tools/Materials


  • Table Saw
  • Router Table
  • Router Bit (1/4" V)
  • Drill
  • Forstner Bit (1" Diameter)
  • Wood Clamps
  • Sander
  • Ruler
  • Pencil


  • Wood - 5.5" x 24" x 5/16" thick
  • Wood Glue
  • Paint/Stain (optional)

Step 2: Box

The box is used to house the chocolate pieces. The build is pretty straightforward.

Step 3: Floor

Cut the floor of the box to the dimensions shown.

Step 4: Box Front/Back

Cut to the size shown.

Step 5: Box Sides

The sides have finger grabs. The final dimensions are shown. I found it easier to cut a wide piece and drill the hole in the center. I then used a table saw to cut the part into two pieces.

Step 6: Assemble Box

Use wood glue and clamps to attach the sides to the floor.

Step 7: Puzzle Pieces

The parts will fit in the box as shown.

Step 8: Blocks

You will be building to these dimensions. The following quantities (numbers represent blocks of chocolate) are required:

  • 2x5 (x1)
  • 2x3 (x2)
  • 2x2 (x1)
  • 2x1 (x2)
  • 1x3 (x2)
  • 1x2 (x2)

Step 9: Notches

I used a V shaped 1/4" router bit to cut the notches for the blocks.

Step 10: Blocks

A table saw was used to cut the individual blocks once the notches were included. At this point, you might want to consider painting or staining the pieces. I used a walnut stain for mine.

Step 11: Block Assemblies

You will need to make these 3 assemblies from the blocks.

Step 12: Glue

I used wood glue and clamps for the joints.

Step 13: Ready to Solve

The puzzle is handed to your test subject in this manner.

Step 14: Final Pictures

The wood cost was about $2 and it took about 3 hours to make. Overall, I'm pretty happy with how it turned out.

Step 15: Stop Motion of Solution

Ok, I was bored. Here is a quick stop-motion of the solution.

Thanks for viewing!

Pocket-Sized Contest

Participated in the
Pocket-Sized Contest

Be the First to Share


    • Mason Jar Speed Challenge

      Mason Jar Speed Challenge
    • Pumpkin Challenge

      Pumpkin Challenge
    • Bikes Challenge

      Bikes Challenge

    9 Discussions


    Reply 2 years ago

    lol...yeah, I didn't know what to call them. I think "puzzlers" is the correct word but that sounds strange as well.


    Reply 2 years ago

    I was thinking of what kind of rubber/foam would have a look/feel of chocolate, but I think that would be hard. Well, easier for me with no router, table, lathe, agreeable wife, etc.


    The thing about this kind of puzzle is that it what we had as kids, not a computer game. We are the true maker generation of bow ties, fountain pens, and slide rules. I mean, the games/puzzles were tactile then, or "3D" in today's parlance. A kid becomes a true problem solver/creator when given a pile of legos instead of a lego "kit"...

    Well done.


    2 years ago

    I like it! Might be enough to make me finally get a router table


    Reply 2 years ago

    Thanks. The grooves could also be made with a table saw and sanding to get the chamfer. I recently picked up the used router table so I'm trying to find uses for it :).


    Reply 2 years ago



    Reply 2 years ago

    Thank you!