Get jiggy with it

Jigsaw puzzles–some people love them, and some people, well, feel like there are better things to do with their time. If you’re among the latter, then you probably haven’t made your own yet. Intrigued? The steps are simple, and the possibilities are endless.

You can use a personal photograph or artwork to create a unique present for friends and loved ones, set up a fun-filled project for your kids, or just make one for your own enjoyment. And if you’re a puzzle fanatic, get ready to take your obsession to a whole new level.

Jigsaw puzzles are a great way to teach kids problem-solving skills, but be aware of age limits when using the construction materials described in this 2torial. Since foam board can be torn, and the bits of it swallowed, don’t let children under age three use these puzzles, even if the pieces are particularly large.

Decide on an image

The best thing about making your own jigsaw puzzle is that you get to decide what it’ll be. Here are some guidelines and possibilities to help get you started:

Size and clarity. Whether you pick an image or create your own, it should be large and clear enough so the person completing the puzzle can make out the minor details. You probably don’t want to create a puzzle smaller than a square foot (30 by 30 centimeters)–unless you’re the devious sort.

You’ll be using foam board (a flexible board consisting of a thin piece of foam sandwiched between two pieces of poster board) as a backing. These boards typically measure 20 by 30 inches (51 by 76 centimeters).

Create your own image. Any two-dimensional art–painting, crayons, pastels, pencil, and so on–can be applied directly to the puzzle’s surface or pasted on if the artwork is on paper (either by using the original art or a clear, color photocopy). Just make sure the medium you choose is dry before you start cutting the puzzle.

Note: For certain art mediums, such as charcoals, pastels, and oil paints, the foam board will need a primer layer of paint called gesso, available in art supply stores. Apply the gesso to the foam board with a brush, wait for it to dry, then apply your artwork.

Use an existing image. Photographs work well for the personal touch–you can have a photo enlarged by a professional developer, or do it yourself on a color copying machine. Other options include a favorite work of art (as long as it’s printed on paper), a poster, or a photocopied collage.

You’ll also want a copy of the image for the puzzle-solvers to use as a reference, as well as a box to keep everything in. Make sure the image is large enough to include appropriate details, and either put it inside the box or attach it to the lid.

Decide on a pattern

The type of pattern, or the design of how the pieces will fit, depends on the level of difficulty you want. Once again, you have a lot of choices, so start with the two main possibilities–interlocking or not–and work from there:

Non-interlocking. This means the pieces don’t “lock” together through knobs and recesses, but simply fit together with mirroring contours. The advantage of using this pattern is that it’s easier to cut and put together. On the other hand, you have to be more careful assembling it, and keeping it together once it’s completed, since the pieces can be easily knocked apart.

Interlocking. This is what most jigsaw puzzles use, with the pieces locking together and staying together until you pop them apart. Each piece typically has at least one outward knob and one recess, where the knob of another piece can fit.

Everything in between. Don’t feel limited by these two possibilities. You can mix them together in your pattern or even create theme puzzles, where the shapes of some of the pieces actually correspond with the image on the puzzle. Just remember to keep the shapes fairly contained–that is, without long, thin parts that could tear easily.

You can also get creative with the shape of the entire puzzle. Who says it has to be square? A circle or triangle can work just as well. Or you can continue a theme to the entire silhouette of the puzzle itself! Just remember that puzzles without squared sides can be harder to assemble, since the assembler won’t have the flat edges or corners as a cue for placement.

Attach the image to the board

Once you’ve decided on what you’re going to do, gather your materials and go for it.

First, apply your image to the foam board. If you’re using original art, then paint or draw it on the foam board and allow enough time for it (or the spray fixative) to dry completely.

If you’re attaching an image, acid-free spray adhesives work the best. They provide an even coat and won’t yellow the paper with age, like normal glues. Just spray the adhesive on the back of the image. If you use liquid glue, apply it with a small paintbrush to the back of the image so you get an even coat.

Once the back of the image is covered, gently lay it on the foam board so it’s completely flat. It’s very important that the image not have any wrinkles or bumps once it’s attached (smooth them down gently with your fingers if you see them). If there are any air pockets, the image can peel off or tear once the pieces are cut. To help it dry correctly, lay the foam board so the image is facedown on a clean surface, then put even weight on top of it (a few large books work well). Let it dry at least a few hours; overnight is best.

Once dry, flip the board faceup and use a utility knife or scissors to cut the foam board to fit the image size (or cut it to the particular shape you want).

Draw and cut your pattern

As you design your jigsaw pattern, you’ll probably have to erase quite a bit, so use a pencil and draw lightly.

Flip the board facedown and draw your jigsaw pattern. Start with each corner and work along the edges. Once the edges are covered, keep rotating around the edges, working inward until you reach the center pieces. Remember to avoid long, thin shapes that can easily tear, as well as pieces that are uncommonly small (less than a square inch, or 2.5 square centimeters). Once you have the pattern completed, retrace it with a dark pen.

Set the puzzle on a surface that you won’t mind cutting into (like an old worktable), and start cutting with your utility knife, following the traced lines, piece by piece. For the best results, use a fine-tipped knife with a narrow, triangle-shaped blade. Start with the pieces on the outside edges and work inward toward the center. Work slowly and carefully. Press hard so you cut through on the first try. Keep the blade perpendicular to the foam board to get a clean edge.

As you finish each piece, lay it out in a separate area, image side up. Attach each newly cut piece to the previous one, so when you finish cutting, you’ll have a completed puzzle. Then once you’re done, the real fun begins. Jumble the pieces, spread them out, and put them back together all over again.