3 Maple Burl Puzzles

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Project by ScrollSawVideo posted 02-17-2011 11:42 PM 1678 views 2 times favorited 5 comments Add to Favorites Watch

As you can see, there is no scrap burls in my shop. Every burl will have a project coming out of it. Pictured are three of my latest puzzles.
The first one is 4 3/4×3 1/2 inches with 46 pieces. I used an imperfection in the wood as a focal point.
The second one is 4 1/4×2 7/8 inches with 34 pieces. This one I used a freehand style cutting.
The third one is 5 1/4×2 1/2 inches. This one has a natural Maple bark edge.

Cutting this kind of jigsaw puzzle has become a passion for me. In the past I have been mainly a fret cutter but needed a new avenue.

I start with lumberyard lumber. After looking at the pieces gather dust for a few months, I resaw the lumber into strips about 3/8 inch wide. After this I use the Performax to do a majority of the sanding. Even after a high number sandpaper is used I can still see sanding marks so out comes the hand scraper to give the final smoothness. LOL….sanding each piece of wood to my standard usually takes about 1-3 hours each. I map out the puzzle pattern on the wood and cut out using a Flying Dutchman puzzle blade. After cutting I use the Mirka 320 sanding sponge to remove any left over pencil lines. Last, I dip each piece in Danish oil and let dry for 8-10 days. Approximate time on each puzzle, depending on size, is around 4-6 hours each. Look at for more examples of my puzzles.

Thanks for looking. I hope you enjoy these.

-- Karl. N. Atlanta

5 comments so far

View jschmitz1949's profile


56 posts in 3059 days

#1 posted 02-18-2011 12:07 AM

these are neat – and beautifully rustic!

View LittlePaw's profile


1571 posts in 3076 days

#2 posted 02-18-2011 04:53 AM

WOW, nice work, workmanship and design!

-- LittlePAW - The sweetest sound in my shop, next to Mozart, is what a hand plane makes slicing a ribbon.

View Bogdanovich's profile


120 posts in 2763 days

#3 posted 02-18-2011 06:39 PM

This is more than nice.

-- My English and my woodworking are matching skills.

View ScrollSawVideo's profile


46 posts in 2907 days

#4 posted 02-20-2011 01:11 AM

The puzzle shown above sold in 2 days…..whooooohooooooo.

-- Karl. N. Atlanta

View Karson's profile


35120 posts in 4399 days

#5 posted 02-20-2011 01:14 AM

A great use of small materials. But they are great looking.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware soon moving to Virginia †

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