July/August 2007
Volume 50
Issue 4
Archived Project Plans
Project Articles
woodworking Plan Low-Cost Outdoor Storage
woodworking Plan Luggage Rack
woodworking Plan Castle Puzzle
woodworking Plan Owners Gallery
woodworking plans Letters from Owners
Academy Notes
ROUTING: Professional-looking joinery & accents for your projects
Service Pointers
Bandsaw Service Pointers
What's New
Kreg Deluxe Bandsaw Fence
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The Wooden Castle Puzzle

Building & assembling the frame
Following the details in figure 2 and the Bill of Materials, make the main frame (C,D) from 3/4” x 1” cherry stock. Sand the main frame pieces and stain with the same cherry stain used on the puzzle pieces. Finish with a coat of urethane.

Glue the backing board (A)/cutout board (B) assembly to the main frame (C,D) components. As an added touch, use 1/4” x 14” strips of pine cut to proper lengths (See Bill of Materials) to create a mat frame (E,F). Sand with 220-grit sandpaper and glue into position.

Once all the glue has dried, apply a final coat of urethane over the entire assembly.

Finally, you’ll want to make a simple, unusually-shaped stand (G) from 1/4” plywood (See Fig. 2 for details.).
Figure 2








Bill of Materials
(dimensions in inches)

A Backing board (1) 1/4 x 8 x 8-3/4 (plywood)
B Cutout board (1) 1/4 x 8 x 8-3/4 (plywood)
C: Main frame stiles (2) 3/4 x 1 x 10-3/4 (cherry)
D: Main frame rails (2) 3/4 x 1 x 10 (cherry)
E: Mat frame stiles (2) 1/4 x 1/4 x 8-3/4 (pine)
F: Mat frame rails (2) 1/4 x 1/4 x 8 (pine)
G: Stand (1) 5/16 x 4-1/2 x 4 x 3-3/8 (1/4” plywood)

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