South Sudan added to Africa Puzzle

Only a country since 2005 so I can be forgiven for missing it first time around

Now added

Africa puzzle finished

There is a lack of photos for the next stage which was to stick 3mm MDF to the back of the puzzle, followed by the drilling of a 3mm hole in each of the 42 pieces and gluing a small peg into each one.

There are 3 countries that I deemed to small to cut on a puzzle this size, The Gambia, Lesotho and Swaziland. Their outlines have been drawn.

I have not added the country names to the backboard. Some countries are just to small.

Started the African Map Puzzzle

Kids are back at school so I can make progress on the African Map Puzzle.

First job was to cut the ply as large as possible.

This is the largest I can cut out on the scroll saw

Next stick painters tape to surface of the ply. This blue tape is dual purpose. It lubricates the blade and reduces the chances of burning the wood as it cuts and it facilitates the removal of the pattern.

 

The pattern is then stuck on top of the blue tape ready for cutting out

 

 

Cutting out completed.

Sample Puzzle Map, Africa Regions

Here is a sample of what I can do.

The puzzle is cut from 6.5mm Birch Ply ( contraplaqué en bouleau ) and backed with 3mm MDF of which I had a few small pieces in my workshop.
I printed an image found on the web and stuck it to the wood and then cut around it.


All wooden children's puzzles I have ever seen have been made from birch ply. Normal ply available from Casto, Bricodepot, Leroy Merlin etc is made from a soft wood which splinters easily and is generally of very poor quality with gaps often appearing between the plies.

We have been unable to find a stockists of 6.5mm birch ply in, or around, Caen. I can buy it in very small quantities on the internet but it is very expensive to buy this way. I find this strange as 6.5mm is a standard size ( manufactured typically in Finland, the Baltic States or Russia) and is readily available in the UK. I will probably buy a sheet (2.4m x 1.2m) when I am in the UK in August.

I think any thicker that 6.5mm on a large puzzle would be too heavy.

I have only painted one piece of the puzzle. I am not an artist and yellow was the only coloured paint I had.

The holes in the backing board were made in error when I set the depth of the drill incorrectly.

I think that by writing the names of the countries underneath the piece provides an element of surprise.

What size are the Montesorri Puzzles? Cutting the smaller countries, Togo, Benin, and Gambia might present a problem especially if we want to put a peg in each one.

Tell me what you think. I can post this sample to you if you like.