Tag Archives: IPP

Hex Stair (Part Two)

Following on from by first post on the Hex Stair (Part One), I’m moving from the initial copy which I made for myself and realised it was far too big, onto a smaller version, which I’ll be making a small run of puzzles to sell. Making things smaller adds new challenges so read on to see what I had to do to overcome them.

The original and the new scaled down versions

The original and the new scaled down versions

As you can see above, I have seriously scaled down the size of the pieces, which makes for a much more manageable puzzle size. I am slightly torn in all honesty; I love the big solid chunky copy I made initially, but also appreciate that it’s far too big for most people, and the more compact size is far easier to work with … or is it?

Lots of cleanup required after milling the boards

Lots of cleanup required after milling the boards

Having decided on the dimensions for this smaller version, I cut and milled my stock, cutting what I hoped would be enough sticks to make a reasonable run of puzzles. The pile of sticks looks like a lot, but I have no doubt that I’ll get through them pretty quickly. If you’re interested, the woods are (from left to right) Paduak, Wenge, Curly Maple, Purpleheart (on top), Birdseye Maple, Red Palm, Paduak.

All the sticks cut and sized ready for making into blocks

All the sticks cut and sized ready for making into blocks

I didn't have paper handy so some curly maple left over from the rough cutting worked great

I didn’t have paper handy so some curly maple left over from the rough cutting worked great

With everything setup, I started batching through the cutting of the pieces, and despite needing 42 pieces per puzzle, once everything is setup, this goes fairly quickly. I keep my digital calipers beside me and keep checking the cuts as I go to make sure I’ve not had any errors introduced, as the biggest reason I have found for a puzzle not fitting correctly is tiny differences in the tolerances of cuts. Anything more than about five thousands of an inch between pieces and the fit will not be good enough. Ok, five thousands is pretty small I hear you cry, but I try to get my pieces to less than two thousandths to make sure I don’t have problems. Sadly I’ve learned from experience that even small margins like this make the world of difference and cause a lot of frustration when gluing pieces together in the type of puzzles I’m making.

Several puzzles worth of pieces cut and ready to be beveled.

Several puzzles worth of pieces cut and ready to be beveled.

Having batched out a good few pieces; enough to make a few puzzles; I take a break from cutting the pieces and move to the router to add the bevel to the edges of the pieces. I find that taking a break like this keeps me focused and alert, rather than becoming complacent as the motions get repetitive, and it’s all too easy to lose focus … and as I have already experienced, a tiny lapse can be very costly!

Bags of blocks beveled and counted out per puzzle.

Bags of blocks beveled and counted out per puzzle.

With all the pieces cut and beveled, it’s time to start gluing the puzzles together. You’ll remember the crude jig that I made for the initial puzzle, which worked pretty well. I found out though that with the smaller pieces, there’s not a lot of gluing surface, and I made the pieces almost as tall as the are wide. (They’re not perfectly square!) Because of this, it’s easy for the pieces to get misaligned, so I felt I needed a better jig…

Hex Stair Speciality Jig

Hex Stair Speciality Jig

Speciality Jig showing piece in place

Speciality Jig showing piece in place

Speciality Jig showing piece completed

Speciality Jig showing piece completed


As you can see this jig is a little more advanced than the original, however the main drawback is that it will only work for this puzzle, and only for pieces cut to the exact sizes that I have used. While that may seem like something of a waste, for the most part, the jig is made from offcuts from the sticks I used so really it’s putting small cuts which would otherwise be used in my fireplace to good use. The jig is a very snug fit for each piece, and as you can see each piece is well supported meaning that each completed piece I make in the jig will be identical and it’s also very quick to use, since there’s no way to misalign a piece. With this jig, it takes around 15 minutes to make each individual puzzle piece, meaning that I can make a complete puzzle in around 2 hours (allowing for the curing time of the glue). This as nearly 2.5 times faster than previously. While it may seem like it still takes a long time, I’d rather take my time than rush and end up with a useless pile of firewood. After all, a high quality puzzle doesn’t get made in a minute.

With the jig doing all the hard work for me, it doesn’t take too long to make a copy of the puzzle, to the point where the outside faces get sanded and then finish applied. In Part Three, I’ll cover some of the finishing process.

One thing I noticed when assembling this version of the puzzle is that it’s actually easier to put together than my original version. One of the reasons is that I’ve found a particular rotational move which allows the alignment of the pieces to happen much more easily. I didn’t find this on my original version, I think partly because it is much more squat than the new dimensions. The extra height makes it easier to do this move (although I have gone back and found that it is also possible on the original copy).

Hex Stair (Part One)

Not too long ago, I posted a few pictures of some of the puzzles I’d been making on Facebook. One of those was a copy of Oskar van Deventer’s design “Oskar’s Domino Tower”. I’ll write about that in another post, however when I did, my good friend Derek Bosch got in touch about a similar design he’d created called Hex Stair. To his knowledge, the design had never been made, and I decided that it would be a fun puzzle to try to build after seeing the design.

Hex Stair Solved

Hex Stair Solved

As you can see the design is based on a hexagon. So that means making cuts at a 60 degree angle. To do so repeatedly, I was going to need a new jig, specifically a cross cut sled setup for that angle. I’ve gone through the process to create a cross cut sled before, so I’m not going to go over that again here. I used the same basic MDF construction using 3/4″ boards, and I cut myself some maple runners as guides for the sled. If you want more info about creating the sled, then have a look at my post about going From Square Sticks to Cubes. Clearly rather than a 90 degree angle on the sled I was looking for 60 degrees, and with a little tuning, and a few practice cuts, I had the sled producing perfect angles.

60 degree Crosscut Sled.

60 degree Crosscut Sled.

To do that, there’s no point in measuring just one cut. Rather it’s better to make 6 cuts, creating a hexagon frame, and bring those pieces together. If they come together with no gaps, then you’re golden. If not then you need to adjust the angle of the backstop on the sled. Ed: The reason for doing this is that it multiplies any error in your sled by a factor of 6. I didn’t get things perfect on my first attempt, so I adjusted slightly and then re-cut the test pieces. This time I was pretty close and didn’t think I was going to get much better so I called it good. To make tiny adjustments, a strip of tape can be used to adjust the angle. Obviously I could create a sled with a variable back stop, and have screws to push or pull it for a perfect fit, but for now I’m not looking at spending too much time. If I find many puzzles which require 60 degree angles that I want to make, then I’ll consider making a more advanced jig. Ed: What is it about us that we’re never happy with what we have, we always want it to be better?

With the sled ready, I milled my stock, selecting some Paduak, Birdseye Maple and Red Palm that I’d had sitting for a while, and got to work on the new jig. There are 42 pieces required to make this puzzle and given that there are 7 layers, I decided to create a band in the centre of the puzzle. Since it’s never been made before, I’m not biased by something someone else has done, and I thought it would look fairly good. You can be the judge, based on the photos! I got to work cutting 18 pieces each of the two main woods, and 6 pieces for the centre ring. With that done, I took the pieces to the router and added a very subtle bevel to the long edges. I quickly found out here that beveling the pointed edges can’t be done on the router as there is nothing for the guide to reference off, and given the thin nature of the pieces, this would be a fairly dangerous cut, so I opted not to bother. I think in the finished puzzle, it works out very well, as it makes it look as though there’s seven rings, rather than 42 individual pieces. Again it’s all personal taste, but I’m happy with the results!

Gluing the pieces together into a finished puzzle presented me with a few interesting challenges. Firstly, it’s not square, so my current gluing jigs are no use. Also the puzzle is fairly tall, with each individual piece of the puzzle having a very small footprint, making it unstable without a lot of support, so ensuring that everything is glued up perfectly alighted is an interesting challenge.

60 degree basic gluing jig

60 degree basic gluing jig

My first gluing jig was a pretty simple progression from my square corner gluing jig. Using the 60 degree crosscut sled I was able to create a simple base and walls at the correct angles, and re-inforced the centre angle with a couple of the equilateral triangles I’d cut when I was cutting the original pieces. The inner surface was waxed to prevent glue sticking to it (and hence sticking the pieces to the jig) while I was working. This worked pretty well, and I created the original puzzle using this jig, and the pieces I’d not glued in place to support and align the piece I was gluing.

Supporting the pieces while gluing

Supporting the pieces while gluing

Supporting the pieces while gluing

Supporting the pieces while gluing

All said it worked fairly well, and the end result was reasonable. I did find that there were a couple of pieces which hadn’t lined up perfectly. But I used an interesting trick to fix that. With the six pieces of the puzzle together in the solution shape, I put the whole thing in the microwave for about a minute and a half on high. With my now warm puzzle, the glue is softened enough to allow the pieces to shift slightly if enough pressure is applied. By doing this I was able to re-align the couple of pieces I wasn’t happy with and get a near perfect fit. Now I’m not suggesting that this is a solve all for bad initial gluing as it really isn’t, bit in the few hundredths of an inch that I was misaligned on one or two pieces it can be corrected, rather than throwing away an entire piece.

Puzzles and Beer...

Puzzles and Beer…

Me holding the puzzle

Me holding the puzzle

Scale next to a soda can

Scale next to a soda can


Overall I’m pretty happy with the results, although the size is certainly an issue. As you can see it’s a big puzzle, and not really realistic in terms of making them in a production run. It seems that I’m pretty good at forgetting how big a puzzle ends up when you glue all these ‘small’ pieces together. Part of the learning curve I’m on just now, but it’s all valuable information.

In part two I’ll look at making the puzzle in a more sensible size, and talk about the unique jig I built to help. Since I’ve had several requests, in part three I’ll talk a little about finishing.

California Puzzle Party – hosted by Nick Baxter

It’s been a while since I’ve updated the blog, as I’ve been pretty busy with work, and with progress on a certain puzzle I’m making, but I thought this one was worth the wait. Before I say much more, I’ll give you two pictures. As ever, click them to see a larger version…

Nick Baxter's entire collection of Stewart Coffin Originals

Nick Baxter's entire collection of Stewart Coffin Originals

Nick Baxter's entire collection of Stewart Coffin Originals

Nick Baxter's entire collection of Stewart Coffin Originals

Yes, that table, measuring probably 16′ long is a lifetime of work from puzzle designer, builder and inspiration to many; Stewart Coffin. In a rare occurrence, Nick who graciously invited us to a puzzle party at his house, had the entire collection out and on display for cataloging. Not only that, but he was happy to let us play with the puzzles, and for others demonstrate some really unique movements to some plain looking puzzles. To see the collection through the pictures I took really doesn’t do it justice.

The video shows a scan of both sides of the table, and hopefully gives a better idea of what’s there. Obviously, the larger images below show the collection in more detail, but sometimes a video is more useful. Something incredibly interesting that a few of the people who were there commented on, including Scott Peterson, who is well known for some stunning Coffin reproductions was that the size of the puzzles gets smaller as the numbers get higher. Now this may fit with how many people thing about your skills as a wood worker progress over the years. Start big, get smaller as you go, but we came to a different conclusion. When Stewart started making puzzles, he was able to get his hands on lumber in much greater thicknesses than is readily available today. So as the years go on, and the lumber gets thinner, the size of the puzzle pieces you can make gets smaller. Maybe other people out there have thoughts, but that was ours!

The series of photos which follow, show the collection. Enjoy.

The collection

The collection

The collection

The collection

The collection

The collection

The collection

The collection

The collection

The collection

The collection

The collection

The collection

The collection

The collection

The collection

The collection

The collection

The collection

The collection

The collection

The collection

The collection

The collection

The collection

The collection

The collection

The collection

All I can really say personally is WOW. Thank you to Stewart Coffin for creating so many unique and beautiful puzzles for us to play with, and thanks to Nick for letting us see them!

Now that you’ve stopped drooling, the collection of Coffin’s was only one small part of the day.

There were many familiar faces present, including Bram Cohen, Alan Boardman, Abel Garcia, Scott Peterson, Derek Bosch, Marc Pawlinger, Stan Isaacs and a few faces I didn’t recognise. Nick’s wife was also there, and had laid on quite a spread of food including some excellent chilli to keep the puzzlers well fed throughout the afternoon.

As this was the first time I’d been to Nick’s house I had a good wander around to see what puzzling delights were on show. In the puzzle room there’s quite a few familiar puzzles on display. I recognised a couple of Kagen Schaefer’s boxes, as well as Berrocal’s and many of Eric Fuller’s puzzles, plus a pretty nice collection of Marcel Gillen’s work. I didn’t have time to play with many of the puzzles on the shelves, but I’ll come back to the Marcel Gillen puzzles…

Nick's puzzle room

Nick's puzzle room

Nick's puzzle room - Berrocal

Nick's puzzle room - Berrocal

Nick's puzzle room

Nick's puzzle room

Nick's puzzle room

Nick's puzzle room


While I was browsing the room, Nick announced that he was going to be doing a guided solve of the Host gift from IPP 17, made by Gary Foshee. Well I didn’t want to miss that, having seen the Trolly Car sitting on Nick’s dining room table when I walked in. It is a sequential discovery puzzle where each part of the puzzle opened reveals new tools, or parts of tools which must be combined in some clever ways to be able to get to the next part of the puzzle. The object is to remove the four passengers, whose names are inscribed in plaques at their feet. I’ll do a full review of that puzzle in part two of the writeup for the Puzzle party as I took pictures throughout the disassembly, but here’s a couple of quick pictures to let you see just how much is hidden in the puzzle.

The IPP17 Host Gift

The IPP17 Host Gift

The IPP17 Host Gift

The IPP17 Host Gift

IPP 17 Host Gift

IPP 17 Host Gift

After Nick had spent 20 minutes or so taking the puzzle apart, with suggestions from the collected audience, a few of us remained around the table for the assembly process to restore the puzzle to its start point, including myself, Abel and obviously Nick. As we talked the topic of the Revomaze puzzles came up and I mentioned that I’d solved all so far except the Gold, and we discussed my thoughts on the series and also Gold Specifically. Abel asked when I’d received mine as he didn’t have his and we talked a bit more as Nick struggled to remember exactly where each piece came from! After he was finished, he asked me to join him in the puzzle room, which of course I did.

The Gillen Collection

The Gillen Collection

There he picks up the small Marcel Gillen rolling pin puzzle and hands it to me asking “See what you make of that”. So I start playing and quickly find that there’s a maze in there, and the handle of the rolling pin is what is navigating the maze. Sound familiar? Anyway, after a couple of minutes, I find that there’s a sprung pin in there which rides on top of a maze, and gives a distinctive click when you fall off, forcing you to back track to the start and retry. The weight of this puzzle is significant, certainly more than that of a Revomaze Extreme. I quickly find that I can navigate the maze, and moving slowly I can feel the edges of the maze much like you can with practice on the Revomaze. Nick mentions that the larger, entirely aluminium rolling pin is even heavier when I point this out. So I must have a go of that too! The larger one took it’s toll on me. I ended up with my hands silver from all the aluminium dust having spent around half an hour working on it! I believe I made it around half way though the maze as I has able to get from the start to the other end of the pin consistently before falling off. Nick who’s opened the smaller puzzle from IPP13 but only made it half way in the larger says he thinks that’s around half way! For those who have solved a Revomaze, these puzzles significantly predate the revomaze, but lack the ‘quick reset to start’ found in the earlier Revo puzzles.

I did have a play with the much smaller, and lighter Eis Puzzle which I did solve. But I’ll be going back to complete these rolling pins as I’m pretty sure with a little more time I can crack both of them!

Also on that Gillen table was a fair collection of the Chess pieces, so I took the much better picture above since I had remembered my camera that day, unlike the last time at Stan’s

I also spent a while talking to Nick about the current Black Letter labs puzzle series as Nick and I are working together with a team of Renegades solving those. At this time, our team is #2 in the overall rankings with a combined solve time for the first 4 puzzles of 3 days, and it’s been a lot of fun (When we finished both artifacts 3 and 4 we were briefly in first place overall). I’ll write more about that in another post though.

I had a great day and it was good to see a lot of familiar faces. Come back in a few days when I’ll hopefully be able to post the rest of the writeup, including some items from Alan Boardman and his miniature puzzles, and the Trolly Car guided solution.

Three Piece What ‘sit

This entry is part 6 of 6 in the series IPP 31

At IPP 31 in Berlin George Bell exchanged his Three Piece What ‘sit made by Bernhard Schweitzer in the New Pelikan workshop. The goal, and the only hints you get are to “Assemble the 3 pieces to an allside symmetrical 3D shape”

The Three Piece Whatsit Pieces

The Three Piece Whatsit Pieces

This great looking puzzle is made from Maple and Robina and measures 2.75″ x 2.75″ x 2.75″. The three pieces are a good size in your hands and give little away about how they should be combined. Playing around you’ll quickly find several ways that two of the pieces can be joined, which leave no room for the third to fall into place.

I probably spent around 10 minutes before I found the correct orientation of the first two pieces to allow the third to drop into place correctly, leaving a very pleasing solution shape. Taking it apart and photographing it for the review, it then took me around another 10 minutes to get it back to its solved state again. Since then I’ve taken it apart and put it back together again several more times, and I can solve it fairly reliably now. I’m sure if I left the pieces separate for a while then came back to it, it would take a little time before I could solve it again, so the level of difficulty is reasonable on this one.

Interestingly, at the at same time as George designed this puzzle, Don Charnley also designed the same puzzle, and named it Donz Q’b. The interesting thing is that the puzzles pieces are mirror images of each other. So you may find this puzzle referred to by either name, but in the end it’s the same puzzle.

Solution shape of the What 'sit

Solution shape of the What 'sit

I’ve deliberately, not included the picture of the solved shape as part of the gallery since that’s part of the challenge, but since it’s readily available in a number of places on the web, if you want to see it, click on the image above to see the full shape. Overall, a fun puzzle, and highly recommended if you can get a copy.

Judges Gavel

When you think about iconic items in society today, the crack of a Judges Gavel has to be up there. So when Michail Toulouzas took that iconic item and made it into a puzzle, there was little doubt that it would be special. And at IPP 31 in Berlin, the Judges Gavel won First Place.

Judges Gavel

Judges Gavel

Mike recently offered a number of these puzzles for sale and with an award winning puzzle, how could I possibly pass up the opportunity to add one to my collection, so without any thought I clicked ‘buy’ on the Puzzle Paradise auction! Update: Since posting the review, the last of the gavels on paradise has gone.

The goal of the puzzle is to remove the Mexican Ebony ring from the handle of the gavel. Sounds simple enough. So before you ask, no it doesn’t come off over the handle. The inner diameter of the ring is too small to allow it to do that, and clearly it’s not going to come off over the hammer end!

Closeup of the stunning woods used.

Closeup of the stunning woods used.

Measuring 4.25″ x 1.25″ x 9″ for the hammer, this version is slightly larger than the IPP entry. Made from a stunning combination of Mahogany, Lignum Vitae and Mexican Ebony, the Puzzle looks stunning. Mike tried to keep the choice of woods dark, rich and full, not fancy, and I’d agree with most of that. The woods certainly are dark and rich, but the Lignum Vitae on the handle and base have such depth and character, that I can’t classify them as anything other than fancy. When you turn the puzzle over in your hands, the light reflects off the wood with an almost magical property… and I love it! The whole puzzle has a warm feel to it; it exudes quality and has a feeling of something expensive and high quality.

Ed: Now returning to your regularly scheduled review …

Ok, so I like the look and feel of the puzzle. You get that!

Sadly I wasn’t in Berlin for the IPP, however those who were (Brian I’m thinking about you) recall that you could tell when someone was working on it thanks to the crack of the gavel hitting the block.

Since Brian had already commented in his review that there was more to the puzzle than just hitting the gavel, I was really looking forward to trying this one out myself. Like Brian I wasn’t disappointed. The puzzle is a piece of master craftsmanship, and there are subtle details that you’ll need to understand to be able to solve it.

Open!

Open!

It’s a clever puzzle, and needs (by my count) 5 steps to solve it and remove the ring. Some of those are fairly obvious, but others are well hidden and really need you to think about what’s going on. The beauty is that this is a solid puzzle, and designed to be used in the way the object it mirrors would be. So giving it a good whack is both part of the solution, and incredibly satisfying as well.

Mike's signature

Mike's signature

On the base of the wooden block, in possibly some of the neatest handwriting I have seen in a long time is Mike’s signature and a few details about the puzzle including the number in the run and the date it was made.

Ssssh ... we're working!

Ssssh ... we're working!

There is one last detail that Mike included with the puzzle, and that’s the small leather round to sit on top of the base to help deaden the sound… but when it makes such a nice sound, why would you want to? Not to mention that it would cover up the beautiful grain that you can see below.

The base looks stunning with the rich grain

The base looks stunning with the rich grain

In summary, this is a great puzzle, and highly deserving of its first place prize. If you’re quick, you should be able to add one to your collection, and in my opinion, you’d not be disappointed if you did!

Daedalus

Daedalus is one of the IPP31 Design entries from Gregory Benedetti. A simple 3×3 cube where the goal is to take the pieces apart. As an eight piece puzzle, from the outside it doesn’t seem that this can be too challenging, however as is so often true, this puzzle is far from simple! I was fortunate enough to be able to buy my copy from Puzzle Paradise when Gregory offered a few for sale there after the IPP.

Daedalus in Walnut

Daedalus in Walnut

Measuring in at just under 3″ x 3″ x 3″ my copy is made from Walnut with some very interesting grain running through the cubes. Gregory made the puzzle available in a number of different woods including Marblewood and a few others. Made by Maurice Vigouroux this is a beautifully crafted puzzle with bevelled edges on each of the cubes and a mirror smooth finish to the sides of the cubes, which I’ve learned myself can only be achieved through very accurate cuts.

The puzzle consists of a main outer frame, with 7 moveable pieces contained within that frame. What makes this rather different to your standard 3×3 cube is that the pieces have rods and tracks embedded in them, making a maze of sorts through which the pieces must be moved in order to remove them from the puzzle. Of course this is made more challenging because the internal maze changes as you move the pieces around, since the maze is part of the pieces themselves!

Now if that wasn’t hard enough, Gregory makes things more complicated (and removes the use of Burr Tools by throwing rotations into the mix too. When you find out how to move the pieces around you find that you have created enough space to allow some very interesting rotations to take place, including some that completely change the orientation (top->sides etc) of some pieces, which will either get you closer to the solution or just further lost in the maze.

Growing arms and legs to get the first piece out

Growing arms and legs to get the first piece out

The puzzle doesn’t remain in a cube shape for long, and appears to grow arms and legs as you manipulate the pieces. It took me just a few seconds to find the first piece which moved, and then several minutes more before I found the second piece which would move. After this several more hours were spent sliding pieces back and forward, and exploring rotations and really trying to understand what is possible in the constraints of the pieces. Lets just say that there’s plenty of dead ends, blind alleys and red herrings (yes, this puzzle is like the Tardis … much bigger on the inside than the outside) to keep you busy. It certainly kept me busy for more than long enough. Taking 22 moves to remove the first piece it’s no small challenge. In total there’s 22.8.7.2.2*.1 to remove all the pieces. (* 2 pieces are removed at this point) I’d call that a challenge!

Daedalus open

Daedalus open

After several hours spent over several days, I had this puzzle open, and all the pieces out. As you can see all the pieces are unique, and other than the tracks that make up the maze, there are no internal voids when closed. Returning the puzzle back to the starting point is every bit as much of a challenge. Since it had taken me a couple of days to open this one, I had forgotten the orientation of the pieces and even which pieces came out first, so it took another few hours to get this even close to being a cube again. All in all great value.

The gaps between pieces

The gaps between pieces

One small issue in my copy is that the outer frame which forms the largest of the pieces isn’t perfectly square which does mean that the pins can be seen through gaps in the cubes. While it doesn’t prevent the puzzle working in any way, and certainly doesn’t make things any easier, it does slightly spoil the surprise of finding out that this is not an ordinary cube, by giving that little secret away early.

Overall I really enjoyed this puzzle, and I’m very happy to have a copy. I know I’ll keep going back to this one as the challenge is tough but not impossible, and the range of movement that is achieved is excellent, making you want to go back to it time and again, simply because you can’t believe that some much complexity can fit into a 3×3 cube.

Thanks for this one Gregory, it’s a great puzzle, and I love it.