CLEVER

PUZZLE BOXES

© 2016 Cruz Bay Publishing, Inc.

 d
Weekent
Projec

Clever
Puzzle
Boxes
Your own ingenuity
is the key to creating
and opening these
attractive boxes.
Japanese puzzle boxes have been
around for over 100 years. They’re
opened by following a sequence of
“moves” to reveal the hidden treasures
stored inside. And while the design
featured here is fairly simple (only five
moves), building one of these creative
little boxes is sure to be a test of your
woodworking skills, as well as your
attention to detail.
WOOD SELECTION. You’ll notice as you
look over this plan that it doesn’t
require a large amount of lumber to
build one box. That makes it the perfect
project for using an exotic species that
you’ve been saving for a special project.
Hardwoods from
left to right: wenge,
sapele, and redheart.
Our designer, Chris Fitch, couldn’t
decide on one wood that he liked the
best, so he decided to build several
puzzle boxes, as you can see above. Just
one cautionary note before starting: The
boxes have very tight tolerances and
require parts to slide in grooves and
against one another. For that reason,

How-To: SHAPE THE TOP & BOTTOM

3 a. END VIEW
1 2 &/16

A A Aux. miter !/4

fence

PART NAMES
Top
Fence !/8" straight
a. END VIEW bit a. END VIEW
PART NAMES b. !/16 !/8
PART !/8
NAMES !/8
FIRST: This is !/8
!/8" #8 x 1#/4" Fh woodscrew
straight #8 x 1#/4" Fh woodscrew
!/4 !/8" straight NOTE: Sand chamfer
!/4 on one end of top only
bit FIRST: This is bit
FIRST: This is
SIDE VIEW

Grooves First. Rout a groove along
the edges of the top and bottom, as
PART NAMES
well as one end of the top.
Trim Tongues. Remove part of Rabbet & Chamfer. The other end of the
the tongue on the long edges top has a rabbet on the underside. This same
and the end of the top piece. end then gets chamfered (detail ‘b’).
PART NAMES

1 FIRST: This isWoodsmithPlans.com WS22620 #8 x 1#/4" Fh woodscrew ©2016 Cruz Bay Publishing, Inc. All Rights Reserved.
FIRST: This is
 3#/4
6#/4 6#/4
NOTE: Top, bottom,
and sides are made A TOP
be sure that the wood you’ll be using is from #/8"-thick
thoroughly dry and acclimated to your hardwood
shop. This will minimize any wood
movement after the project is done. B SIDE
Also, the majority of the parts for 3
Chamfer this B
end of top
each box require the use of 3⁄8"-thick only
hardwood. Since lumber is typically
not sold in this thickness, I opted to use A BOTTOM
1⁄ "-thick material and planed PART NAMES
2 it down.

#8 x 1#/4" Fh woodscrew
PARTS CONSTRUCTION
Building the puzzle box requires FIRST:mak-
This is a. b. &/16 !/8 !/4 c.
ing several parts before the entire box !/4
gets assembled. Locking rabbet joints !/16
!/8 INTERIOR VIEW !/8 !/8
are used throughout to hold several of (side only) !/8 A
!/8 A !/8
the box pieces together. After being cut B
B
to size, a lot of these parts have grooves, !/8
dadoes, and rabbets that are made 2!/4 !/8 FRONT
&/16 VIEW
almost exclusively at the router table !/8
B

using an 1⁄8"-dia. straight bit. Sticking !/8

A A
with one size bit also helps minimize !/4
SIDE SECTION VIEW !/4
machine setup times. PART NAMES
TOP & BOTTOM. The How-To box at the
PART NAMES

How-To: ROUT THE SIDES

PART NAMES
bottom#8ofx 1#/4"
the Fhprevious
woodscrewpage walks
you through the process foris
#8
FIRST: This
cutting
x 1#/4" the #8 x 1#/4" Fh woodscrew
Fh woodscrew
joinery
PART NAMES on the top and bottom of the
FIRST: This is FIRST: This is
box. These two pieces are very similar. 1 2 Rout rabbet
on both edges
The exception being that the top has
8 x 1#/4" Fh woodscrew
B B
a couple additional rabbets along PART the NAMES Fence
FIRST: This is
Fence
ends, as well as a small chamfer on the
underside of one end. The #8 upper right
x 1#/4" Fh woodscrew
drawing, along with details ‘b’ and ‘c,’ FIRST: This is !/8" straight a. END VIEW !/8" straight a. END VIEW
provide all of the dimensions you’ll !/4 bit !/8
bit !/8
need to make these parts. !/8
!/4
IDENTICAL SIDES. Much like the top and
bottom, the two sides have a lot of
joinery going on, as well. But the good
news is that these two pieces are iden- Grooves in Sides. Continuing with the Deep Rabbets. You’ll need to raise
tical. If you take it one step at a time, 1⁄ " straight bit, rout the two grooves the bit and readjust the fence to rout
8
PART NAMES to make.
they’re pretty straightforward on the inside PART NAMES
face of each side. the rabbets along the edges.
The How-To box at right shows most PART NAMES
#8 x 1#/4"
of the detailed Fh woodscrew
joinery cuts you’ll need 3#8 x 1#/4" Fh woodscrew Aux. 4
to make on each side FIRST: panel.is x Again,
This #8 1#/4" Fh woodscrew FIRST: This is
fence B For more stopped
dado information,
these are all done at the router tableFIRST: This is see page 7
PART NAMESwith a straight bit. The only operation B
Fence
that needs a little more explanation is Edge of
/4" Fh woodscrewthe stopped dadoes. 2!/8 bit
a. END VIEW
Stop cut
FIRST: This is The stopped dado near one end of !/8 when front edge a. &/16
!/8
!/8" straight of workpiece
each side piece is simple to complete bit !/8 reaches this mark END
(Figure 4). But the stopped dado near on fence VIEW !/8
the other end requires a slightly dif-
ferent procedure. Turn to Shop Notes
on page 7 to see the process I used to Through Dadoes. Now lower the bit Stopped Dadoes. The stopped
PART NAMES
make these cuts. You can then set these and rout the through dadoes near the dadoes on the inside face of each
four parts aside for PARTnow.
NAMES They’ll be end of each side piece. side hold the dividers in place.
#8 x 1#/4" Fh woodscrew
assembled later.
#8 x 1#/4" Fh woodscrew FIRST: This is

2 WoodsmithPlans.com
FIRST: This is WS22620 ©2016 Cruz Bay Publishing, Inc. All Rights Reserved.
 a. FRONT VIEW b. FRONT VIEW c. #/8 TOP VIEW
#/8 (/16 F !/8
E
1!/8
1!/8 1!/8 1&/16 !/4 !/8
D !&/32 !/4 C
!/8 (/32 !/8
1!/16 #/8"-dia.
%/8
D !/8

Top !/8
4 F
LOCK
D
3!/2 DIVIDER
3
E END
2#/16 3!/4
PART NAMES C
d.
END PART NAMES
DIVIDER !/4 !/8 !/8
2#/16 4
#8 x 1#/4" Fh woodscrew !/4
#8 x 1#/4" Fh woodscrew #/4
FIRST: This is Bottom !/8
!/2 FIRST: This is !/4
C D #/8
3 !/8 G

Side
H #/4
!/2
LOCK E
H F 14°
END !/16
KEY
14° bevel both !/8
NOTE: Slide edges of slide
is made from 4 !/4
#/4 F
!/8"-thick hardwood. Key is G SLIDE
!/4"-thick hardwood. All other !#/16
parts are #/8"-thick hardwood (/16

Completing the BOX PARTS PART NAMES

!/4
END VIEWS SECTION
VIEW

While the top, bottom, and sides make the bottom

#8 x 1#/4"and sides. And second, the
Fh woodscrew
up the most visible parts of the box, lock divider contains a shallow recess
FIRST: This is
the final six parts contain the majority that will allow a slide and key assem-
of the “locking” features that allow the bly to move sideways as part of the
box to open and close. This includes a opening process. Start by cutting the
slide and key assembly that starts the two dividers to size.
opening sequence. But first, a couple of Figures 1 and 2 below show the steps
internal dividers are needed. needed to form the tenons on the ends
TWO DIVIDERS. The dividers serve two of the dividers. The end divider is com-
purposes. First, they provide rigid- plete after the second step, but the lock
ity to the box when they are glued to divider still needs the shallow recess
on its outside face. Figure 3 provides
the details for forming this recess. After
removing the bulk of the waste at the
drill press, make sure to square up the
walls of the recess with a chisel.
TWO END PANELS. After cutting a couple
of blanks to size for the two end pieces,
take a little time to look over the main
drawing above, as well as details
‘b’ and ‘d.’ This will provide a good
understanding of these parts and the

How-To: MAKE THE SHORT TENONS & LOCK DIVIDER RECESS PART NAMES

1 #8 x 1#/4" Fh woodscrew 2 3 !/4" Forstner

Fence bit
FIRST: This is C D Tall aux.
fence
D
C D
PART NAMES Drill out waste,
a. then clean up
END with a chisel
" Fh woodscrew VIEW
a. END !/8
FIRST: This is
!/8"
straight
!/8
VIEW a. END
SECTION
bit !/8 !/8" straight VIEW
bit !/8
#/8
PART NAMES !/4

#8 x 1#/4" Fh woodscrew
Short Tenons. It’s This
FIRST: backis to the router Nibble Away Waste. Raise the router Recess. Remove the bulk of the waste
table to form the short tenons on the bit in steps to remove the rest of the for the shallow recess in the lock
ends of both divider pieces. waste at the top of each tenon. divider at the drill press.

PART NAMES
3 WoodsmithPlans.com WS22620 ©2016 Cruz Bay Publishing, Inc. All Rights Reserved.
#8 x 1#/4" Fh woodscrew
 jobs they do to make the box function How-To: ROUT THE ENDS & SLIDE
correctly. These parts won’t be glued in
place, but rather will slide in the dadoes 1 !/4"onrabbet ends a. !/8 END 2 fence Aux.
a. END VIEW
cut in the box sides. VIEW !#/16
The operations shown in Figures 1, !/4 E !/4
2, and 3 at right are completed on both PART NAMES
F
E PART NAMES E F
end pieces. This just consists of a few
PART rabbets
NAMESand grooves, again made at the
#8 x 1#/4" #8 x 1#/4"
Fh woodscrew
Rout !/8"
!/8" Fh woodscrew
rabbet on
b. END b. END VIEW
VIEW NOTE: Make
router table. Figure 4 shows the finalFIRST: Thisstraight is bit top edge
FIRST: Thisfirst
is
!/4 several passes
(/16
#8 x 1#/4" Fh woodscrew
groove needed only on the end piece. to rout bottom
!/4 edge rabbets F !/4
PART NAMES NOTE: Cut !/4"-wide end
FIRST:The
This lock
is end, however, still needs a PARTin
rabbets NAMES
two passes
couple more steps to finish it up. The
#8 x 1#/4" Fh woodscrew #8 x 1#/4" Fh woodscrew
first is to create a dovetailed groove Form the Shoulders. Make the rabbets Lower Rabbets. Remove the
on the outside face. This groove FIRST: This is
mates along the topThis
FIRST: edge
is and the ends of both rest of the waste for the rabbets
up with the slide that’ll be PART NAMES
cut to size end pieces at the router table. on the bottom edges of the ends.
PART NAMES
shortly. A single pass with a 3⁄4"-dia.
#8 x 1#/4" Fh woodscrew
dovetail bit is all it #8
takes (Figure 5).
x 1#/4" Fh woodscrew 3 4
Sources on page 8 showsFIRST: where Thisyou
is E
FIRST: This is a.
can find this dovetail bit. END
VIEW
A through slot centered on the freshly !/8
a. END VIEW
made groove is next. This slot makes !/8"
!/8" PART NAMES E straight
room for the key to be attached to the #/8 bit !/4 !/8
straight F
slide during assembly. I formed the slot bit
PARTatNAMES #8 x 1#/4" Fh woodscrew
the drillPARTpress by making a series of
NAMES
overlapping holes, as shown in Figure 6. FIRST: This is
#8 x 1#/4" Fh woodscrew
Square up the edges
#8 x 1#/4" Fh woodscrew with a chisel. Groove Ends. Using the same bit, rout End Panel Groove. One more
FIRST:SLIDE
This is
ASSEMBLY. The two final pieces the groove along the edges of both end groove is needed on the end piece to
FIRST: This is
of the puzzle box are a slide and key. pieces
PARTtoNAMES create the locking rabbet. complete the joinery on this part.
When brought together, they form the
PART NAMES slide assembly on the lock end of the #8 x 1#/4"5 Fh woodscrew
6
box. The key is simply cut to size from FIRST:FThis is #/8"
h woodscrew a long piece of 1⁄4"-thick stock. Forstner
bit
FIRST: This is The slide requires a little more atten-
a. END VIEW
tion. Since this piece needs to fit in the #/4
dovetailed PART grooveNAMES
in the face of the 14° dovetail bit !/8 #/4

lock end, I planed PART an extra-long

NAMES blank
#8 x 1#/4" Fh woodscrew
so that it was a shade thicker than what Drill out waste, then
FIRST: clean up edges with a chisel
I ultimately x 1#/4" This
#8 needed. is
(Just a
Fh woodscrew hair under
PART NAMES
3⁄ " is what I started with.)
16 FIRST: This is Dovetailed Groove. Make the Through Slot. A slot centered in the
Next,#8both edges
x 1#/4" of the slide need to
Fh woodscrew dovetailed groove in the outside face dovetailed groove provides space for
be beveled. But making these cuts pres- of the lock end using a 14° dovetail bit. the key to attach to the slide.
FIRST: This is
ents a challenge — there’s a potential for
Stop cut
7
Extra-long
AMES
the beveled edge to slip under the router blank 8 G

table fence after it passes the dovetail bit. Waste

To prevent this, I raised the workpiece Carrier Slide Start cut with
screw G board end line slide end line
by taping it to a carrier board (Figure 7). Waste at this mark
This is
After beveling both edges, check the fit in 14°
dovetail a. END a. SIDE SECTION VIEW
the lock end. Use sandpaper to sneak up bit VIEW 1!%/16
1%/16
on a sliding fit. Then, holding the slide in Double-sided
Slide
Start cut !/16
End cut line
end
place in the groove, sand it flush with the tape line Slide end
#/4
surface of the lock end. #/4 !/4" straight bit
A shallow recess on the inside face of
the slide provides a mounting point for Bevel Edges. Attach the extra-long Recess. The recess on the inside face of
the key. Figure 8 provides the details for slide blank to a carrier board to cut the slide is made by lowering the workpiece
making this at the router table. Now cut the bevel on the edges of the slide. onto the bit and routing to the end line.
the slide to final length.
PART NAMES
4 WoodsmithPlans.com WS22620 ©2016 Cruz Bay Publishing, Inc. All Rights Reserved.
#8 x 1#/4" Fh woodscrew
 FIRST: Slide top on
box until front end b.
NOTE: Drawing shows
extends past a.
box in open position Top !/16" roundover
after assembly. Numbered lock end
steps show how to close Top Top
Lock Lock
Top divider divider
Chamfered End
end of top Side
Key Side
THIRD: Slide top
back to fit into Key
Side
end dado and Slide
flush with back Slide
Lock end surface of end End
PART NAMES PART NAMES extends
NOTE: After partsPART
are NAMES Lock Lock past
Slide locked into position, ease bottom
end end
all outside edges
#8 x 1#/4" Fh woodscrew
#8 x 1#/4" Fh woodscrew
of #8 x 1#/4"
puzzle boxFh woodscrew Bottom Bottom Bottom
FIRST: This is FIRST: This is
FIRST: This is
End SIDE SIDE FRONT
SECTION VIEW SECTION VIEW SECTION VIEW
(open position) (locked position) (open position)
SECOND: Slide end up so
it's flush with top
FIFTH: Move edge of side c. Ease edges after all
slide into position parts are in locked position
so that ends are flush FOURTH: Slide lock end up to
with sides, locking all to bring top edge flush End
parts into closed position with top surface of top
End divider

Assembling the BOX Side

TOP SECTION
VIEW
Side

PART NAMES
At this point, all of the parts PART for
NAMESthe So at this point, you’re Lock divider
d. Lock end Side
puzzle box are complete. But before you just
#8 x 1#/4" Fhlooking
woodscrewfor a snug fit
can start putting things together
#8 x 1#/4" perma- between
Fh woodscrew these five parts.
FIRST: This is Key
nently, it’s wise to take a littleFIRST:
timeThis
and The slide, two ends, Side
is
do a dry assembly. This ensures there and top require a little Slide TOP SECTION VIEW
won’t be any surprises when you start more attention. These (open position,
through slide)
adding glue down the road. pieces need to slide eas-
The How-To box at the bottom of ily in their respective
this page and the box at the top of the grooves and dadoes. Spend some time Figures 1 and 2 below. Note that you’re
next page provide the sequence to fol- checking the fit of each part and sand- only gluing the bottom and dividers
low when doing the test fit. The bot- ing where necessary. into one side for now. The other side is
tom and two dividers are the easiest Once you’re satisfied that things are added at the end of the assembly.
to check. They’re eventually glued into working smoothly, go ahead and glue MOVING PARTS. Now put the slide in
the grooves and dadoes in the sides. the initial pieces together, as shown in position and glue the key into the shal-
low recess in the slide (Figure 1, top of

How-To: GLUE BOTTOM & DIVIDERS TO SIDE next page). You can access this recess
through the slot in the lock end. Use just
enough glue to hold the key in place.
1 2 Bottom
End
divider Materials & Supplies
A Top/Bottom (2) 3⁄
x 33⁄4 - 63⁄4
8
Bottom
B Sides (2) 3⁄
x 3 - 63⁄4
8
C End Divider (1) 3⁄ x 23⁄ - 31⁄
8 16 2
Lock
divider Side D Lock Divider (1) 3⁄ x 23⁄ - 31⁄
8 16 2
PART NAMES
E End (1) 3⁄ x 3 - 4
8
F Lock End (1) 3⁄ x 3 - 4
8
x 1#/4" Fh woodscrew Side NOTE:
Mortise in G Slide (1) 1⁄ x 3⁄ - 4
8 4
FIRST: This is
lock divider H Key (1) 1⁄ x 1 ⁄ - 1 ⁄
4 2 2
should be
facing out
!/2"x 7!/2" - 24" Hardwood (1.3 Sq. Ft.)
B E B F NOTE:
Add Bottom First. To start the Dividers Up Next. The dividers are
C D Plane
assembly, one edge of the bottom is then added by gluing them into the A A to final
thickness
glued into a side panel. stopped dadoes in the sides. G H

5 WoodsmithPlans.com WS22620 ©2016 Cruz Bay Publishing, Inc. All Rights Reserved.
PART NAMES
 You don’t want any squeezeout gluing How-To: COMPLETE THE BOX ASSEMBLY
the slide to the end.
The end and lock end are simply set 1 2 NOTE: Lay box on side
into position against the bottom and side. to install end and lock end
End
No glue is needed for these parts. The Slide
Lock end
lock end may need to be slightly “wig- Lock end
slot Bottom
gled” into position Slide is flush
PARTsoNAMES
the key rests in the PART NAMES with edges of
recess in the lock divider (Figure 2). lock end
PART NAMES Now#8 youx 1#/4" can carefully glue the
Fh woodscrew #8 x 1#/4" Fh woodscrew FIRST: Position key
Key is in lock divider mortise
other side panel to the bottom and
FIRST: This is
a. FIRST:
TOPThis
VIEWis centered
dividers as shown in Figure 3. Again, in slide
" Fh woodscrew Slide mortise mortise SECOND: Slide lock end
FIRST: This is
be very careful to not get any glue on Slide Key
tongue into side dado
the end or lock end parts. Lock end slot
The final piece to this puzzle is to
slide the top in place. Both ends need to
be lowered slightly to let the top slide Add the Key. A small amount of Set Ends in Place. The end and lock end
into position. Make sure the chamfered glue is all that’s needed to secure are set in position next. Do not use any
end of the top is facing the lock end of the key to the slide. glue on these parts.
the box (Figure 4). To wrap things up,
I eased all of the outside edges of the 3 4
box with sandpaper.
KEY TO UNLOCKING. Having assembled Side Top
the puzzle box, you probably have a End
pretty good idea of how to open it up. Chamfer
Bottom
The photos below simply serve as a End is
NOTE:PART Side stopped
NAMES slid
reminder of the steps to follow. dadoes fit over down
FINAL DETAILS. Since there are moving divider tongues
parts on this project, I didn’t want a #8 x 1#/4" FhSide
woodscrew
dadoes
fit overThis
endisSide
thick finishPART“gumming”
NAMES things up. So I FIRST:
tongues Slide in open
opted for one light coat of urethane fol- position and lock
lowed end slid down
#8 x 1#/4"by
Fh awoodscrew
single coat of wax to keep Dividers
things sliding Lock end
FIRST:smoothly.
This is You can turn Riser block
to Sources on page 8 to get the details
on the finish I used. Now hand your One More Side. The other side of Top. With both ends in their lowered
box over to an unsuspecting victim and the box can now be glued to the positions, the top is slid in place with
sit back and enjoy as they try to figure bottom and dividers. the chamfer facing the lock end.
out how to get it open.

How-To: UNLOCK THE PUZZLE BOX

1

4
3
5
2

{ First, move the slide to the side { Now, slide the top towards the { Finally, the top of the box slides
until it stops. Then shift the lock end. This releases the other back toward the end. It can be
entire lock end assembly down. end, allowing it to slide down. completely removed, if desired.

6 WoodsmithPlans.com WS22620 ©2016 Cruz Bay Publishing, Inc. All Rights Reserved.
 PART NAMES Shop Notes PART NAMES

#8 x 1#/4" Fh woodscrew
" Fh woodscrew Stopped Dadoes FIRST: This is 1 Front edge Auxiliary 2 &/8
Front edge Auxiliary
of bit fence
FIRST: This is The sides of the puzzle box have 2!/4 of bit fence
stopped dadoes on their inside faces to
!/8"
ART NAMES hold the dividers. The stopped PARTdado
NAMES on straight
one end is simple to make by routing bit

woodscrew to a stop line on the#8 router

x 1#/4" Fhtable fence,
woodscrew
Start with
FIRST: This is
as shown in Figure 1. However, the
FIRST: This is Stop when edge of edge of workpiece
stopped dado on the other end requires workpiece reaches line on fence at this line
a different technique. Here you need to a. Line on SECTION VIEW a. Line on
SECTION VIEW
fence Front edge Front edge
mark the start line on the fence and then of bit fence of bit
lower the workpiece onto the spinning Rout direction
2!/4
bit (Figure 2). You can then complete the
cut by running the bit out the other side Dado waste
of the workpiece.

7 WoodsmithPlans.com WS22620 ©2016 Cruz Bay Publishing, Inc. All Rights Reserved.
 MAIL Project Sources
ORDER • Lee Valley
SOURCES 14° Dovetail Bit . . . . . . . 16J17.57
General Finishes
generalfinishes.com The puzzle boxes were finished
with one coat of General Finishes’
Lee Valley Arm-R-Seal Oil & Urethane Topcoat
800-871-8158 followed by a single coat of wax to
leevalley.com
keep the parts sliding smoothly.
Manufacturers and retailers will
periodically redesign or discontinue
some of their items. So you’ll want
to gather all the hardware, supplies,
and tools you need before you get
started. It’s easy to adjust dimen-
sions or drill different-sized holes
to suit your hardware.

8 WoodsmithPlans.com WS22620 ©2016 Cruz Bay Publishing, Inc. All Rights Reserved.