instructables

6 Piece Wooden Burr Puzzle

by rhallett

Who doesn't love a puzzle? no clue what you're doing, and the host of the
gathering has been judging you for that whole time.
They're those little things you find on someone's
coffee table in an awkward social situation and pick Little do you know, they have no clue what to do with
up just to give yourself something to do. It's only after it either.
a good 10 seconds of turning it over in your hands
and pressing random parts that you realise you have

6 Piece Wooden Burr Puzzle: Page 1

Step 1: Basic Blocks

Cut 6 identical blocks of timber (I used Kauri pine,
but most softwoods are suitable :D) into blocks 40mm
x 40mm x 120mm. I used a combination of a
compound saw and table saw for this.
Label each piece so you can tell which one is which,
(much like you would with twins. Or sextuplets.)
Use a pencil and steel rule to mark the sections
you're going to remove. See the reference above for
what each piece should look like. In this scale, each
"pixel" is 40mm cubed, so you could block it out with
a 40 x 40 grid if that helps.

Step 2: Mark and Slice

With the steel rule and a scribing tool, (a craft knife works too,) cut shallow marks around the previously
determined outlines. This will provide a sharper edge when you start chiselling out chunks.

6 Piece Wooden Burr Puzzle: Page 2

Step 3: Chunk Removal

Sharpen your chisels folks, this may take a while.
Start by sawing (I used a Japanese saw,) straight
down into the block (only as deep as you need!)
where you've marked. Cut some extra, parallel
grooves to help in the chiselling process. The more
the merrier.
chunks of the wood. Be cautious not to split it among
the grain (which I definitely did not do, *cough* but if I
did, I would have filled it with PVA glue and clamped
it together overnight. ahem.)
When most of the wood is removed, hold the chisel
flat on the wood, diagonal to the grain, and shave.

Grab a wooden mallet and start chiselling away It's not as easy as it looks but don't be discouraged,

you've still got 4 more pieces to practice on!

Step 4: Filing

Chisel not cooperating? Just grab a file and smooth that sucker down!

Step 5: Test Fit

Try to fit your pieces together. Don't cry when they don't fit. Just keep filing and chiselling away at each surface.

Above is a video that shows how the pieces interlock. I have watched it so many times...

6 Piece Wooden Burr Puzzle: Page 3

 https://youtu.be/C7X01QXaUB8

Step 6: Finishing

When it's all the right shape and fits together, sand linseed oil for a minute then let them dry.
each piece down lightly.
THEN YOU'RE DONE! It can sit happily on your
I had some rough edges so I rounded them with a belt bookshelf, and the best thing about no one being able
sander. (Just incorporate your mistakes into a design to pull it apart is that no one will see the mistakes you
element and try better next time, am I right?) made on the inside :D

Choose your finish- I just dunked each piece in

6 Piece Wooden Burr Puzzle: Page 4

Nice work! I love little puzzles like this. Well done : )

6 Piece Wooden Burr Puzzle: Page 5