Dowel routing for the da Vinci bridge puzzle

I highly recommend this puzzle for the aspiring young engineer in your life, because it is the very definition of a smart toy.

The procedure shown here could easily be adapted to mass produce these bridges for craft fairs or for gift-giving. I used 1/2" dowels and a 1/2" core-box bit. It does take quite a few clamps, and making dowels is certainly an art (that looks much easier on YouTube), but the finished project is unquestionably rewarding in that "fits perfect" sort of way. I hope you enjoy.

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For more on making dowels by using this method:
   • How to make the dowel maker  

This is not as easy as it looks. But after some practice and patience it can become a useful skill. I've tried a variety of other ways, and I always seem to come back to doing it this way. I don't round-over my stock first though; I use an octagonal stock that has been chamfered at 45° using the table-saw. When I first rip my stock square, I cut it to nearly the same width as the finished target diameter. Thus, if I'm making 1/2" rod, my square stock will be ripped to just barely over 1/2", and then chamfered at 45°, and then passed through the chisel-shaper.

To watch the assembly solution for the bridge:
   • Assembly of the da Vinci bridge puzzle