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Christmas Presents 2011 - Name Puzzles

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Project by Karson posted 950 days ago 1743 views 5 times favorited 19 comments Add to Favorites Watch

I thought that I’d make some name puzzles this year. I probably have made them for my children, many years ago – but I don’t remember seeing them in the last 25 years. My two younger children don’t have any and my grandchildren don’t have any.

These were items that I made over 40 years ago when I lived in St. Louis. They were a great seller and paid for all of my woodworking equipment and other “Man Toys”

I made them out of Red Cedar because 1) it was readily available – A sawmill in St Louis cut only Cedar. 2) It was easy to cut, 3) It was easy to sand. 4) It smelled good and 5) I didn’t have to finish it because – #4.

My family didn’t see me between Thanksgiving and Christmas because I was making puzzles. I’d sit in the house with a stack of orders, A stack of wood and my alphabet (see picture 1). The sawmill cut all of their boards at 6” wide (at least the ones that I bought) My caps were 3” tall and the lower case letters were 2” tall. All of the lower case were my own design. I needed them chunky to be able to cut the interlocking parts of the letters.

I’ve made many as wedding presents where I’d interlock a big heart as I connected the two names.

The problem with making two names is finding a way to interlock them. Hopefully you have tall lower case letters that could be used to hold the upper name and to lock to it. (I, h,b,d,f,t).

If you look at the second picture, you see that Kevin is supported off only two letters in the lower name. To put Kevin on the bottom gives no additional tall letters. If you can see the trailing letters of Kevins name is sagging because of the saw kerf. What I’ll do to fix that is take a small piece of wood and glue it on the interlocking piece of the “V” where it fits into the “I”. That will take the sag out.

The third picture has some additional tall letters, but it required me to give a small amount of additional space between the letters of the upper name and to spread them out to hit all of my anchor points.

On single layer names, I don’t have that kind of problem. The saw I used in St. Louis was a Sears (Craftsman) 80” bandsaw. I welded my own bandsaw blades and I used 1/16” 32 teeth metal cutting blades. I could almost run it into a cut and then turn the wood around and bring the blade back out the same cut. The blades were very fragile. I would get maybe 1 hr life before the blade would shatter into 50 pieces because of metal fatigue. I would usually weld up about 20 blades at a time, some of those were rewelds where the weld would break before metal fatigue would set in. I was buying salvage bandsaw blades in 100’ coils I also went through a bunch of 1/8” blades also when I was cutting puzzles in 2” thick maple.

I was charging 75 cents a letter and I was getting about $25.00 per hour. I was pretty fast in my processing. That included the drawing on the boards, cutting and sanding all cut edges. I drilled the centers of a, o,b,d. The capital letters had a small hole and a jigsaw to cut out the middle of those letters.

I’m not as fast any more. I figure I’d probably need $3.00 a letter to do them now.

A car mfg approached me to made them for every dealer of their car. I don’t remember the promotion but I did make them a master that they then used to cast them out of plastic.I was always thinking of faster and easier ways of doing this. I approached a Mfg of Lasers, before they were popular. But the cutting is by burning and I didn’t want black edges on the letters.

So this year I’m back in business for about 20 names. My wife keeps dropping new names on my list for some of her contacts.

I need to remake 2 names because of splits in my wood and wain that I didn’t notice when I drew the names. But I’m retired, I’ve got the time.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †





19 comments so far

View Mark Shymanski's profile (online now)

Mark Shymanski

4984 posts in 2311 days


#1 posted 950 days ago

Good looking letters and an interesting story.

Merry Christmas!

-- "Checking for square? What madness is this! The cabinet is square because I will it to be so!" Jeremy Greiner LJ Topic#20953 2011 Feb 2

View lew's profile

lew

9945 posts in 2354 days


#2 posted 950 days ago

Nice work, Santa!!

Lew

-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View BarbS's profile

BarbS

2433 posts in 2684 days


#3 posted 950 days ago

Nice, Karson! They’ll love those! All the best things take time.

-- http://barbsid.blogspot.com/

View Grandpa's profile

Grandpa

3047 posts in 1274 days


#4 posted 950 days ago

Great job and good gifts. Thanks for the story. Merry Christmas

View tenontim's profile

tenontim

2131 posts in 2343 days


#5 posted 950 days ago

Folks like gift best that you make personally. Thanks for the story and the good idea. Merry Christmas.

View Joe Lyddon's profile

Joe Lyddon

7620 posts in 2651 days


#6 posted 950 days ago

COOL!

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: http://www.WoodworkStuff.net ... My Small Gallery: http://www.ncwoodworker.net/pp/showgallery.php?ppuser=1389&cat=500"

View TopamaxSurvivor's profile

TopamaxSurvivor

14589 posts in 2274 days


#7 posted 950 days ago

Looks great form here! Nice work.

-- "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

View Lee A. Jesberger's profile

Lee A. Jesberger

6646 posts in 2578 days


#8 posted 950 days ago

Hi Karson,

That was a good idea. I imagine they would be very good sellers.

Very nice work.

Lee

-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com

View Roger's profile

Roger

14114 posts in 1403 days


#9 posted 950 days ago

very kool gifts

-- Roger from KY. Work/Play/Travel Safe. Kentuk55@bellsouth.net

View helluvawreck's profile

helluvawreck

15404 posts in 1465 days


#10 posted 950 days ago

Karson, you did a wonderfful job on these and they will make wgreat Christmas presents.

helluvawreck
http://woodworkingexpo.wordpress.com

-- If a man does not keep pace with his companions, perhaps it is because he hears a different drummer. Let him step to the music which he hears, however measured or far away. Henry David Thoreau

View Bob Kollman's profile

Bob Kollman

1796 posts in 1789 days


#11 posted 950 days ago

Karson, that is a unique way of making them.
I am slow and it took me awhile to figure out
that they are true puzzle pieces.

-- Bob Kenosha Wi.

View Napaman's profile

Napaman

5315 posts in 2676 days


#12 posted 950 days ago

looks like a good retirement business…!! But its nice its for the kids…

-- Matt--Proud LJ since 2007

View Bob A in NJ's profile

Bob A in NJ

1145 posts in 2598 days


#13 posted 950 days ago

Hi buddy,

Great story, glad to hear you’re making some great gifts and making some cash also. Bob

HAPPY HOLIDAYS!

-- Bob A in NJ

View Grumpy's profile

Grumpy

19313 posts in 2450 days


#14 posted 950 days ago

Very time consuming buddy but well worth the effort.

-- Grumpy - "Always look on the bright side of life"- Monty Python

View PurpLev's profile

PurpLev

8476 posts in 2247 days


#15 posted 949 days ago

these are great Karson!

I love the heartwood/sapwood line in the ‘Savannah’ puzzle.

-- ㊍ When in doubt - There is no doubt - Go the safer route.

showing 1 through 15 of 19 comments

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