Master the COG Wooden Puzzle: A Fun DIY Project to Sharpen Your Woodworking Skills!

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How to Make a Wooden Puzzle


Master the Wooden Puzzle: A Fun DIY Project to Sharpen Your Woodworking Skills!

Are you ready to create your very own wooden puzzle? Whether you're just starting in woodworking or looking to take your skills to the next level, this project will be both fun and educational! In this tutorial, we'll walk through the process step-by-step, helping you hone your marking gauge, coping saw, chiseling, and more! Let’s dive right in!

Tools You’ll Need:

Before you get started, gather these essential tools to make this puzzle:

  • Combination Marking Gauge: For accurate measurements and marking.
  • Coping Saw: Perfect for cutting intricate shapes.
  • 20mm Chisel: Essential for fine detailing and chiseling.
  • Combination Square To help with marking precise angles.
  • Tape Measure: For accurate length measurements.
  • Pencil: For marking your cuts.
  • Bench Hook: To hold your timber securely while you work.
  • Sandpaper: For smoothing rough edges.
  • Clamps: To secure pieces while working.

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Let’s get started!


    Step 1: Prepare the Timber

    Prepare the timber

    Start with a nice piece of 2"x1" timber that’s been planed all around for smooth edges. Cut the timber to the following dimensions:

    • 200mm long
    • 43mm wide
    • 192mm across

    This size will fit perfectly with a 20mm chisel, making it easier to work with!

    Step 2: Marking Out and Labeling Your Pieces

    Marking Out and Labeling Your Pieces

    Before cutting, it’s important to mark out everything accurately.

    1. Set your face and edge: Select one face and one edge of your timber as your reference points. This ensures all your cuts and measurements will be consistent.
    2. Label your pieces: Draw a center line down each piece, labeling them C, O, G to avoid confusion during the process. These markings are essential for aligning the puzzle pieces correctly later on.

    👌Tip: Always measure from the 100mm mark of your ruler for better accuracy. Don’t forget to add the 100mm when measuring!

    Step 3: Remove the Sharp Edges (Ari's)


    Remove the Sharp Edges (Ari's)

    You’ll want to remove the sharp edges from your timber. These are called Aris, and sanding them down will prevent splinters and ensure safety when handling the wood.

    • Grab a piece of rough sandpaper and gently rub down the sharp edges.
    • Run your fingers over the wood to make sure the sharpness is removed and feel how smooth it becomes. Trust us, you’ll appreciate this step later!

    Step 4: Cutting the Timber

    Cutting the Timber

    Now, let’s get cutting! Use your combination square and pencil to mark out the dimensions and cut lines for each piece (C, O, G).

    1. Measure and cut to length: Cut each piece of timber to 200mm long.
    2. Use the coping saw: Once you've marked your cuts, use the coping saw to cut out the shapes carefully.

    Tip: When cutting, always take your time, especially on corners, to avoid mistakes.

    Step 5: Marking the Center Lines

    Marking the Center Lines


    For precision, it’s important to mark the center lines on each piece. You’ll need these lines to guide your chiseling and ensure the pieces fit together perfectly.

    • Use your combination marking gauge to draw a line across the width of your pieces.
    • Measure the center of each piece and draw the lines using a pencil.

    👌Pro Tip: You can also use the center-to-center method to make sure your lines are perfect.

    Step 6: Chiseling and Cutting the Mortises


    Chiseling and Cutting the Mortises

    Now we’re getting into the fun part - chiseling! For this step, you will create mortises that will allow the pieces to slot together.

    • For each piece, use your 20mm chisel and mallet to carefully chisel out the waste areas along the lines you’ve marked.
    • Take your time with this, ensuring the mortise is clean and smooth.

    👌Tip: If you're doing a through mortise (like in the letter O), be extra careful as the wood can break out. Work slowly and from both sides to prevent any splintering.


    Step 7: Fitting the Pieces Together

    Fitting the Pieces Together

    Once you've completed the cutting and chiseling, it’s time to assemble your puzzle!

    1. Take your G piece and fit it into the O piece.
    2. Carefully insert the C piece into the puzzle, and voila! You should now have a beautiful, functional wooden puzzle.

    👌Pro Tip: If you’re having trouble with fit, gently sand the edges to make them fit snugly without forcing them.


    Step 8: Sanding and Finishing Touches


    Sanding and Finishing Touches

    Finally, give your puzzle a little TLC:

    • Sand the pieces smooth with a fine-grit sandpaper to remove any rough spots and improve the finish.
    • Clean up any small marks or imperfections and give everything a final polish.

    Step 9: Enjoy Your Wooden Puzzle!

    Enjoy Your Wooden Puzzle!

    Now that it’s all finished, you can take pride in your work. Try taking the puzzle apart and reassembling it. It’s a fun challenge and a great way to showcase your new woodworking skills!

    Wrapping Up

    I hope you enjoyed making this wooden puzzle as much as I did! It’s a great project to practice your woodworking skills and have fun along the way. Plus, it makes a cool conversation piece for your home!

    As always, if you have any questions or want to share your creations, drop a comment below! Let’s keep crafting and building awesome things together. Make sure to subscribe and check out my other tutorials and woodworking tips!

    Happy woodworking! ðŸ› ️

    Watch the Full Tutorial

    For a detailed walkthrough, watch my video tutorial on YouTube: How to make a Wooden Puzzle| Perfect for practicing marking & chiseling.

    Until next time, happy crafting! 👋

    Location: London, UK