Hi All:
The design was an old Xmas card we had received over the holidays. I used a 1/4" BB ply backer. I used Steve Good's method of attaching the photo to the wood using spray adhesive to the wood and the back of the picture. After about two hours I applied two coats of Mod Podge to the picture. I let that dry overnight. The puzzle measured 7" x 5" .
I cut the puzzle using the FD-SP (superior puzzle) blades from Mike's Workshop. These blades cut great and give you a really tight fit on your puzzle. For the puzzle piece pattern, I went for broke and tried Carter Johnsons free style cutting technique. Needless to say Carter makes it look real easy. When he suggests that you put the puzzle together as you cut the pieces, follow his suggestion. I spent 20 minutes just trying to place the half dozen loose pieces I cut. I ended up with approximately 85+ pieces when I finished.
[attachment=2]bear1.jpg[/attachment]
While I was at it, I figured I would try and make a puzzle out of a coin. I attached a quarter to a piece of 1/4 ply using some clear packing tape and cut it using the used FD-SP blade I had on the saw. I broke the blade due to overheating. So I set up a new blade, slowed down the speed and feed and no problem.
[attachment=1]qtr2.jpg[/attachment]
[attachment=0]qtr1.jpg[/attachment]