I think that these puzzles are pretty cool but I’ve only made two, both “map” style. You could also make ones with individual pieces that come out, see below.
1. Find a map or other item for the inlay.
I used some old National Geographic maps (above). Unfortunately, the Canada one is outdated as it does not show the new territory of Nunavut.
2. Glue the map to the backing and cut it out.
I like Baltic Birch for this purpose but I suppose that tempered hardboard could work as well. Glue the map, let it dry and cut out the outline using your scrollsaw.
3. Trace around the map on another piece of backing. This will be the top piece which is the edge that holds the inlaid puzzle.
4. Draw approximately 1 cm (1.2″) wider around the drawn tracing from #3.
5. Cut out the wider outline.
6. Drill a hole big enough for your scrollsaw blade to fit through on the inside of the inner tracing. Thread the blade through the hole and cut out the centre portion.
You should now have an outer ~1cm. wide outline that the original puzzle should fit inside.