In this project, Bob Holmes shares a creative way to frame a jigsaw puzzle using standard 2×4 lumber. This guide breaks down the steps to create a sturdy and visually appealing frame that enhances any puzzle display.
Materials and Tools Needed:
- 2×4 lumber
- Wood glue
- Dust collector
- Band saw
- Table saw
- Featherboard
- Push stick
- Sanding block
- Japanese pull saw
- Stain
- Plastic paint pyramids
- Card stock paper
Step 1: Preparing the Puzzle Board
Bob begins the project by trimming the edges off the board where the jigsaw puzzle has been glued. He heads to the band saw to make these adjustments, ensuring the edges are clean and ready for framing.
Step 2: Planing the 2×4
Next, he activates the dust collector to plane the surface of the 2×4. This step is crucial for making the wood look presentable and ensuring it’s ready for cutting.
Step 3: Measuring and Cutting the 2×4
Bob takes some rough dimensions for the frame. He adds extra length to each side to allow for adjustments when cutting the miter joints. This foresight is important for achieving a precise fit later on.
Step 4: Cleaning Up the Edges
Using the table saw, Bob cleans up the edges of the 2×4. He emphasizes safety, using a featherboard and push stick to guide the wood through the saw.
Step 5: Cutting the Groove for the Puzzle
With the edges clean, he sets the blade height to cut a groove on the edge of the frame where the puzzle will fit. This involves carefully adjusting the fence and making multiple passes to achieve the desired depth.
Step 6: Test Fit
After cutting the grooves, Bob performs a test fit to ensure everything aligns correctly. This is a satisfying moment as he checks the puzzle’s fit within the newly cut grooves.
Step 7: Making Miter Cuts
Bob sets up for 45-degree miter cuts, which is the next step to create the corners of the frame. Accuracy in these cuts is vital for a clean and professional-looking frame.
Step 8: Sanding the Edges
Before gluing, he sands the inside edges of the frame, ensuring they are smooth since they will be difficult to reach once assembled.
Step 9: Applying Wood Glue
Bob uses wood glue, stored in a mustard bottle, to secure the miter cuts. He emphasizes the importance of gluing the end grain, which absorbs the glue better, ensuring a strong bond.
Step 10: Reinforcing the Corners
To strengthen the corners, he employs a spline cutting jig. This technique adds durability by eliminating the weak end grain joint.
Step 11: Final Assembly and Drying
After reinforcing the corners with splines, Bob lets the frame dry overnight. He returns the next day to flush the edges with a Japanese pull saw.
Step 12: Sanding and Staining
Bob completes the project by sanding the entire frame down to a fine grit, preparing it for staining. He uses a thicker cardstock paper to protect the puzzle from any stain drips.
Step 13: The Finished Product
In the end, Bob presents the completed frame around the Scooby-Doo puzzle, showcasing how a simple 2×4 can be transformed into a beautiful display piece.
This project is a fantastic way to repurpose a 2×4 into something special. Bob Holmes has shown that with a few tools and some creativity, anyone can create a unique frame for their favorite jigsaw puzzles.