These are probably my favorite kind of 3-D puzzles and the best part is I can make them myself. They can be any type or size of wood and have any jig saw puzzle like pattern, there is just no way to go wrong. Mine is made out of pine so it will be easy to stain and sand.
All you need is a scroll saw (I used my dad's new Craftman Scroll Saw to do this and it was so much faster than my off brand scroll saw) and a block of wood.
If this is your first time using a scroll saw then you might like to read step 2, if not then just skip it unless you might want some helpful tips on cutting. I like to sand all of my cubes and stain them so if you dont want to do this just disregard
Important: I will shortly post a picture of my sanded and stained cube.
Step 1: Selecting Your Cube
The largest size my scroll size will cut is a 2in. cube. Its best to start with a plank of wood thats the size of your cube. Make sure you dont get too big for your scroll saw or you could seriously mess it up, the very action that the saw that uses to cut makes it get smaller than you think.
Step 2: Using Your Scroll Saw
The first thing you should know is that the scroll saw cuts by moving up and down very fast. This will lead to pieces of wood flying around if your not careful co make sure you have a tight grip.
Next when cutting your curves it's best to push the cube into the blade then pullback and turn the repeat until you're done.
When you are cutting strait lines you might will want to try and push the cube into the blade and go faster, this not only can break your blade but it makes it so your cut inside the cube is not perfectly up and down because your blad will bend so you can only slide the cube parts together one way (this can be fixed with alot of sanding).
The last is don't try anything your not ready for, just be careful and keep track of all your fingers.
Step 3: Cuting the First Side
On one side draw a puzzle pattern with a pencil then cut allong the line. After you're done take the parts appart and let any sawdust out. It's that simple.
Step 4: Cutting the Second Side
Tape the first cut peices together as even as posible then draw your second puzzle piece and cut it out. After you're done take appart the pieces and shake out any broken pieces (dont worry about broken pieces it's going to happen you can eather glue them back in or just sand over the spot they broke of from.
Step 5: Staining and Sanding
I like to stain my cubes with Minwax Early American stain it's my favorite stain and its very great looking.
The best way to sand a cube is to use a pad you would usually use on a machine but just in your hand make sure you are careful not to over sand anything or the pieces will not look good on the outside.