Wonderful post....Very detailed and I enjoyed your tour.
I tried card stock before and found the same issue of separation. I just use heavier bond paper and it works ideally.
If I may:
I got the bug for kids puzzles one day in May 2009 while I was waiting at the Oncology dept for my treatment. A grandpa had brought his little grandson with him who was 5 years old, and while grandpa went back for his radiation therapy I watched the little boy while I awaited my turn, and he was so bored. Nothing to do and he was a little scared for his grandpa.
I went home that day and made a couple of puzzles for the waiting room and brought them back the next day they were a really big hit.
Then Carter (you all know carter, the puzzle master) got me to try my hand at cutting out a jigsaw puzzle freehand, no over laid pattern. I made one and gave it to a family member with a note attached, that when they were done to please give it to a friend.
There was one caveat, they needed to contact me and let me know where it is.
So far it has traveled to 4 states, and seems to end up at senior centers. 1 person said 63 people had assembled it at one of the senior centers in Seattle. I have rec'd several phone calls thanking me for the use of my puzzle and asking for more. I finally found my way to give back. The team at the oncology center where I got my treatments were so helpful I just had to find a way to repay their dedication and compassion, Cancer is a scary thing to go through.
I made each of them a really cute bookmark, this too was very much appreciated and then i amde a plaque for their wall.
The wolf is the traveling puzzle. The others are in the waiting room bringing smiles to kids faces, I have even seen some of the adults playing with them to pass the time...