I was at someone's house and tried to solve this type of puzzle, but I couldn't. So, I decided to make one at Techshop so I could solve it later. http://techshop.ws/ This puzzle is addicting!
Step 1: How to play
There are 6 puzzle pieces to put in the base. Arrange the puzzle pieces so that 2 layers of the puzzle pieces will fit. The top cover should fit on flush to the edges of the base.
Step 2: Design and Cut it
The files are pretty straight forward. It was designed in Corel Draw. Once the files are done, then it's time to cut! Gather all your pieces. In the file, I made extra nubs in case I lost some.
Step 3: Stain
I probably should have stained the wood prior to laser cutting, but well, here we are. The procedure would still be the same, with just less time fiddling with tiny pieces. Shake up the stain, then take a rag to it and wipe it on the wood. Be sure to have a well ventilated area and wear gloves.
Step 4: Glue - Frame
Using wood glue, glue the outer frame first.
Then glue it to the bottom piece.
Once those are glued, I put all the inside pieces in to keep the frame straight, then clamp it all together.
Step 5: Glue - Pieces
The piece with the 3 holes is a jig to align the sides and to position the nubs. This is not a puzzle piece! The last two pictures shows which pieces to glue on which piece. Glue the nubs on one side first, then let the glue dry. Repeat on the other side.
Step 6: Figure it out!
Now the puzzle is ready to be solved!