Using the mortiserThe mortiser used in this video is an attachment to a standard drill press. Mortisers are used to drill a square hole, this is done by using a hollow square chisel with an auger in the middle. As the chisel is forced through the wood the auger pulls the wood chips up and out the front opening.
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filing the inside of the piecesThis video shows how to file the insides of the three pieces. File carefully as you only want the opening to be just big enough that a piece easily slides through the opening. Use these techniques reduce the amount of tare out that could occur. Remember not to clamp the vise to tight as this could leave marks in the wood.
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using the disc sanderA disk sander is a quick way to sand down the ends of your puzzle pieces. Remember to keep your fingers away from the disk. As always make sure to read and understand your users manual prior to using the machine.
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Putting on the champherA champher is a 45 degree bevel that removes the sharp 90 degree corner. This is commonly done in woodworking for a couple of reasons. A sharp 90 degree corner can cut or injure someone rather easily, by removing the sharp corner the piece becomes safer. A 90 degree be dented easily, the champher helps reduce damage to the piece.
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