The puzzle is about 17" x 11 "
I glued together 2 pieces of 1/4" BB ply, made a small entry hole in one of the piece corners ( I forget which one ) and cut it using a #7 FD UR . I picked a #7 for the wider kerf . I made sure the blade and table were perfectly square and did not force the cut to eliminate any bowing. The idea is to have a perfectly square cut that is wide enough for the pieces to rattle around a bit . after cutting out the pieces I put them back in and flipped it over to sand the back.
I reassembled the puzzle pieces only and flipped them over so I could round the bottom edges slightly . I then rounded over the top edge of the snake in the puzzle frame itself . I wanted the pieces to go in easily as it is for a small child and we all know how quickly they get frustrated!
Debra painted each piece with non-toxic paint and a sponge brush being extra careful not to get paint on the sides. While she was doing this I glued the puzzle frame to a 3rd piece of BB and after it was dry cut the entire stack to size.
The letters are the " rub on " kind she found at Micheal's . They seemed to have worked well.
we reassembled the puzzle and I sprayed it with 2 very light coats of Deft to seal it and then sanded it smooth with a paper bag
We're going to give it to her this afternoon
