Alphabet Puzzle
I wanted make and Alphabet Puzzle.. Blocks with the ABC's what would only fit in the appropriate order in the "Holder". The "I", "N", "O", "S", "X" and "Z" Blocks can all be inserted in the puzzle upside down.
11
Toys
Files Included (2)
ABC Blocks.svg
848 kBABC Holder.svg
262 kB
Materials
1 each 3" X 24" 1/8 thick board for the letters.
1 each 3" X 24" 3/4 thick board to make the blocks which hold the letters.
1 each 10 X 10 inch board 3/4 inch thick to hold the alphabet blocks.
Tools
1/16 bit to cut out letters and pockets to hold letters.
1/8" bit that can cut 3/4" deep
5mm X 20mm Up-Spiral O-flute Router Bi
Instructions
First cut out the letters in the 1/8 board-- I used 1/16 bit; Zero Offset on OUTSIDE. Cut out the pockets to hold the letters in the 3/4" Board.. I used the 1/16 bit for the Pockets Inside with 0 offset.. Then finish with 1/32nd bit with "-.006" offset.. Then cut out the blocks with Zero Offset on OUTSIDE.. I used the 5mm X 20mm Up-Spiral O-flute Router Bit which Shaper sells.. They say you can cut the full 3/4 inch in one pass; I left about 1/32nd, and made a final pass with 1/16th bit to get the necessary detail. Lastly cut out the "Holder.svg".. Cut the Pocket with the 5mm bit to .375" deep. Then make a finishing pass with 1/16th bit. -.003 Inside with a 1/16th bit.. Glue the Letters into the Blocks. Sand and Finish as needed. If you want to use "Corian"-- I suggest fingernail polish for the letters and make them about .002" deep.
