Download the Template to make your own
The finish used in the video is Tried, and True non-toxic varnish, and the Toggle Clamps Used
How I Made 3D Puzzle Cubes for Christmas Stocking Stuffers
Christmas was sneaking up on me fast, and I found myself in that familiar panic of needing stocking stuffers. Instead of running to the store, I decided to get creative in the workshop and build some 3D puzzle cubes. If you’re interested in making a few yourself, I’ve got a template available for download that’ll make the whole process much easier.
Getting Started: Milling and Prep Work
Like most of my projects, I started by milling up some lumber and cutting it to the overall size I needed. Now, here’s a pro tip I’ve learned the hard way: sanding a bunch of tiny puzzle pieces individually is an absolute pain. So I got smart about it and sanded the entire board before cutting it into individual pieces. Trust me, your sanity will thank you for this.
To make sure each piece came out exactly the same size, I set up a stop on my miter gauge and cut out all the parts. I also cut one extra piece that I’d use later for test cuts to dial in the perfect fit. While I was at it, I cut two strips of wood the same thickness as my puzzle pieces to use as setup blocks down the line.
Building the Jig
Now came the crucial part: building a jig to hold the puzzle pieces safely and accurately while cutting. I drew out all the measurements, and they’re available in the same file as the puzzle piece template if you want to follow along.
I grabbed a piece of scrap plywood and cut two pieces—one to attach to my miter gauge and another to act as a hold-down when cutting out the puzzle notches. To set the hold-down piece at just the right height, I used some puzzle pieces as spacers, then screwed the jig together.
With my dado stack installed, I did a couple of test cuts on scrap wood to dial in the width and height before making that first cut on my jig. Then I took one of those spacer blocks I’d cut earlier and used some CA glue to attach it into the notch. This is actually the same method I use when setting up for box joints, so if you’ve done those before, this will feel familiar.
Dialing It In
Once the glue dried, I used the second spacer to position the jig on my miter gauge. I temporarily clamped it in place so I could run some test cuts and adjust it back and forth as needed. After getting it dialed in perfectly, I screwed it down to the miter gauge so it wouldn’t get knocked out of alignment.
Here’s where safety kicked in: I quickly realized that holding these little blocks so close to the spinning dado stack was a bit too sketchy for my comfort. So I added a couple of toggle clamps to the jig. Problem solved.
Cutting the Puzzle Notches
If you’ve ever cut box joints, this process will feel very similar. The main difference is keeping track of the puzzle piece shape so you cut the notches in exactly the right spots.
Following my template, I positioned each block in one of three ways: against the spacer strip, with an already-cut notch over the spacer strip, or butted against a spacer block that was notched over the spacer strip. There was one piece that was shorter than the rest, so I saved it for last and repositioned both the toggle clamps and the top hold-down piece to accommodate it.
The Finishing Touches
Once all the pieces were cut out, I used my little benchtop sander to clean up the notches and make everything smooth. Then I decided to kick things up a notch—literally. I thought they’d look cooler with a small chamfer, so I set up my router table and ran each piece through.
To hold them steady while chamfering the ends, I repurposed my cutting jig by enlarging the notch to allow the bit to pass safely around the pieces. The chamfer bit couldn’t quite reach into the corners, so I grabbed a sanding block and cleaned those up by hand.
And that’s it! A few hours in the workshop and I had a stack of unique, handmade puzzle cubes ready to stuff into Christmas stockings. There’s something really satisfying about giving gifts you’ve made yourself, and these little brain-teasers are always a hit.
I’m the owner of Benham Design Concepts, a mixed media art studio where I design and build custom furniture and other works of art using wood, glass, stone, and various metals.
In this blog, I talk about the art I create, my journey, and the things I learn along the way.