Nostalgic wooden jigsaw puzzle owners and collectors know how upsetting it is to damage a valuable piece to an otherwise perfect keepsake. The following repair instructions were produced for miniature wooden Puzlet Gems, but the instructions apply to full size wooden puzzle repairs as well.
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If a sold out limited edition puzlet is discovered damaged, your only option may be to try and repair it. This is not easy, especially considering how small Puzlet Gem pieces are. With a little patience and a steady hand, you can do it!
For lumber breaks we recommend using Titebond wood glue (aliphatic yellow glue) only. Apply a very light amount of the glue with a toothpick to one side of the break. Press the broken pieces together, and quickly wipe away the excess squeeze. Secure inside a spring-loaded clothes pin, and allow to dry.
For re-securing lifted paper use non-yellowing paper glue (like Elmer’s) very sparingly, and try not to get the glue on the surface/face of the paper. Using a toothpick as an applicator is helpful. NOTE: GO SLOWLY, and be sure to (damp) wipe ANY glue off of your fingers as you go (sticky fingers lift off tiny paper knobs and corners very, very easily).
Tears and creases can be concealed using soft colored pencils, such as Berol Prismacolor pencils.
To fill hollows and voids in the plywood use Elmer’s Carpenter’s Wood Filler, which is very moist and comes in a tube (putty in a jar is too stiff to work with). For greater flow and application control, poke a pin or nail hole in the nozzle of the tube rather than cutting the tip off. Squeeze filler into the void, and use a toothpick or dental tool to pack, shape, and smooth the filler.
If sanding is required after filler is dry, go slowly and get creative! You can use rolled 150 (or higher/finer) grit sandpaper, fingernail files that have been cut narrow, or small needle files that can be purchased at any hardware store. Any of a number of ideas for abrasives can be used. We don’t, however, recommend the use of power tools when working with Puzlet Gems. The puzzle pieces are just too small to hold, and too delicate to subject to normal power tool torque.
Making a replacement piece is nigh impossible for miniature Puzlet Gems (replacement pieces possibly available if the artist has scrap puzlets on hand), but full size piece reproductions are possible to make. Assemble surrounding part of the puzzle with the lost piece, and trace the puzzle piece hole to create a cutting template. (Keep the paper clean as you will be coloring on it after cutting has been completed). Cut a small piece of matching thickness lumber, and glue on the trace using contact cement (not rubber cement). Allow to dry overnight. Cut out the new piece with a scroll saw, very carefully, very slowly. File to fit as needed. Color in the missing image piece as best you can using Berol Prismacolor pencils, or other mediums of choice. Seal surface art only (do not get sealing product on puzzle edges). Allow to dry, and you have your new replacement.
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Wishing you the best of luck in repairing your wonderful wooden puzzle treasures!