3 Ways to Build a Wooden or Cardboard Puzzle Board

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Keep jigsaw puzzles out and organized with these simple build plans
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If you love building puzzles but don’t want them to clutter up your table space, a puzzle board is a perfect solution. Puzzle boards give you a work surface for storing and putting the pieces together, and they’re an easy DIY project that you can finish within a day. Keep reading, and we’ll walk you through puzzle board plans you can build with wood or cardboard.

Easy Puzzle Board Building Instructions

  1. Trim plywood to 36 in × 26 in (91 cm × 66 cm) to fit most puzzles.
  2. Frame the edges of the plywood with wooden trim pieces.
  3. Cut 45-degree angles into the ends of the trim pieces.
  4. Glue and clamp the trim to the edges of the plywood.
  5. Stain the plywood and trim if you want a different color.
  6. Screw handles into the short sides to easily transport your puzzle board.
Method 1
Method 1 of 3:

How to Build a Simple Wooden Puzzle Board

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  1. Trim a piece of plywood to 36 in × 26 in (91 cm × 66 cm) with a circular saw . Choose a flat sheet of plywood from your local home improvement store, and mark the dimensions with a pencil. Use a circular saw to cut the plywood down to size, and then smooth out the cut edges with 200-grit sandpaper . [1]
    • Licensed contractor Lui Colmenares states, “The most important thing when you use a saw is to have goggles” to protect your eyes while you’re working.
    • Almost all 500- and 1,000-piece puzzles will fit on this board with extra room to spread out the pieces, but you can cut the board smaller or larger based on what you need.
    • Most stores will cut plywood to the size you need when you buy it if you don’t have access to tools at home.
  2. Choose your favorite decorative trim from your local home improvement store. Then, use your circular saw to cut the pieces. To finish your puzzle board, cut your trim so you have: [2]
    • 2 pieces that are 36 in (0.91 m) long
    • 2 pieces that are 26 in (0.66 m) long
    • If you’d rather not cut and put together your own puzzle board, using a pre-built bulletin board works great as a puzzle board.
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  3. Cutting angles in the ends of the trim helps them fit together seamlessly when you attach them. Draw 45-degree angles from the outer corners on the ends of each trim piece. Then, cut along the lines with your circular saw. When you’re finished, each trim piece will have a trapezoid shape. [3]
    • If you don’t want to cut angles into your trim pieces, just cut the shorter trim pieces to 25 1 ⁄ 2  in (0.65 m) instead. This creates a simpler joint without extra cutting.
    • Place the trim in a miter box to line up the angled cut perfectly.
  4. Apply a line of wood glue to the bottom of each trim piece and press it flat on top of the plywood so they align with the edges. Fit the trim pieces together so the angled cuts line up, and secure them together with hand clamps . Let the glue set for at least 30 minutes before you continue your build. [4]
    • Clamping ensures the trim doesn’t move around while the glue dries so it bonds completely.
  5. Find a wood stain color you like and apply a thin coat to the wood with a paintbrush. After about 15 minutes, wipe the stain off with a clean cloth and let it dry for a few hours. Then, you can apply a second coat if you want a richer or darker color. [5]
    • Be sure to open windows and work in a well-ventilated area while you’re staining to prevent fumes from building up.
  6. Screw handles into the short trim pieces. Any decorative cabinet handle works well for your puzzle board. Hold the handles against the tops or outsides of the short trim pieces, and mark the screw locations. Drill holes through the trim for the screws. Then, just screw the handles tightly into the trim pieces. [6]
    • If you plan on storing your puzzle board underneath furniture when you’re not using it, make sure to use short handles that don’t stick up too far.
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Method 2
Method 2 of 3:

Wooden Puzzle Board with Drawers

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  1. Cut particleboard and wood trim pieces with a circular saw . This board has a work surface on top and a large drawer underneath for storing loose puzzle pieces. Get a sheet of particleboard and lengths of wood trim from your local hardware store. Use a circular saw to cut the wood pieces to the following sizes: [7]
    • 36 in × 26 in (91 cm × 66 cm) particleboard pieces (2)
    • 35 in × 13 in (89 cm × 33 cm) particleboard piece (1)
    • 35 in (89 cm) pieces of 1 ⁄ 2  in (1.3 cm) square wood trim (3)
    • 25 1 ⁄ 2  in (65 cm) pieces of 1 ⁄ 2  in (1.3 cm) square wood trim (2)
    • 12 in (30 cm) pieces of 1 ⁄ 2  in (1.3 cm) square wood trim (2)
    • 36 in (91 cm) piece of 1 ⁄ 2  in (1.3 cm) square wood trim (1)
    • 36 in (91 cm) pieces of 1 ⁄ 4  in (0.64 cm) wood trim (2)
    • 25 1 ⁄ 2  in (65 cm) pieces of 1 ⁄ 4  in (0.64 cm) wood trim (2)
  2. Set the particleboard so the rough side faces down. Attach the longest trim piece along the top edge of the particleboard with wood glue and attach the 25 1 ⁄ 2  in (65 cm) pieces to the short sides so they’re flush with the edges. Let the glue dry for 30 minutes. Then flip your puzzle board over and use a nail gun to drive nails every 6 inches (15 cm) through the particleboard and into the trim. [8]
    • The first piece of particleboard and trim pieces create the bottom frame for your puzzle board.
  3. Measure 13 inches (33 cm) in from the remaining long edge on the particleboard and mark the spot. Glue a 35 in (89 cm) trim piece horizontally across the mark. Leave the glue to set for 30 minutes and then flip the puzzle board over to secure nails every 6 inches (15 cm) along the trim. [9]
    • The center trim piece prevents the drawer from sliding deeper into the puzzle board and getting stuck.
  4. Apply lines of wood glue on top of the trim pieces so they’re covered thoroughly. Place the second large piece of particleboard on top of the trim so all the edges are flush. Push the particleboard onto the glue and secure it with clamps . Let the glue set for 30 minutes before unclamping the pieces. [10]
    • The top piece of particleboard forms the work surface where you build your puzzle.
  5. Arrange the long pieces of trim on the top and bottom and the shorter pieces on the sides. Apply lines of wood glue onto the trim and press them down so they’re flush with the edges. Then, use your nail gun to drive a nail through the trim and into the particleboard every 6 inches (15 cm). [11]
    • The trim on top frames your puzzle board to stop loose pieces from easily sliding off.
  6. Set the smooth side of the particleboard face-down so the drawer can slide better. Place the 4 trim pieces along the edges so they’re flush with the sides. Apply lines of wood glue to the backs of the trim pieces and clamp them to the particleboard for 30 minutes to dry. [12]
    • Position a cabinet handle onto the front of a long trim piece on the drawer and mark the hole locations. Drill holes into the trim and use a screwdriver to attach the handle so you can easily pull the drawer open.
    • The drawer lets you store your unused pieces so they stay safe when you're not working on the puzzle.
  7. Use 200-grit sandpaper or an electric sander to smooth out the tops of the trim pieces. Try sliding the drawer into the open slot on your puzzle board. If you can easily push it in and pull it out, then you’re finished! [13]
    • If the drawer still gets caught or stuck, then sand the trim pieces more so it can move smoothly.
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Method 3
Method 3 of 3:

Portable Cardboard Puzzle Board

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  1. Glue felt or paper onto a tri-fold display board . Choose solid-colored felt or decorative paper so puzzle pieces will stand out against it. Get enough material so it’s 2–3 inches (5.1–7.6 cm) longer than each side of the tri-fold board. Spread white school glue on the front of the display board and press it flat onto the felt or paper, and give it a few minutes to dry. [14]
    • Tri-fold display boards are a great starting point since the flaps can fold over and protect the puzzle when you’re not working on it.
  2. Fold the felt or paper over the edges, and pull it tight so there are no wrinkles. Use white school glue or hot glue to secure the loose edges. [15]
    • If you want to hide the edges of the felt or paper, apply a strip of duct tape over them instead. Give your puzzle board a little pizzazz by personalizing it with patterned duct tape .
  3. Flip the display board over, and measure the edges with a ruler or tape measure. Cut strips of cardboard that are 1 in (2.5 cm) wide to the edge lengths. Apply hot glue to the back of the strips and press them along the edges on the front of your puzzle board. These strips become the frame that prevents puzzle pieces from sliding off the board. [16]
    • Paint or cover the cardboard strips with felt or paper if you want them to blend in with the rest of the board.
  4. Fold the sides of your puzzle board in so the flaps are closed. Measure halfway down the height of the board and make a dot on each fold 1 in (2.5 cm) from where they touch in the middle. Make a 2–3 in (5.1–7.6 cm) loop of felt or ribbon and glue it down to one flap. Glue a button to the spot on the other flap to finish your board. [17]
    • When you work on your puzzle, make it in the middle section of the tri-fold board. When you want to put it away, just fold the flaps over and wrap the loop around the button to keep your puzzle safe.
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      Warnings

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      Things You’ll Need

      Simple Wooden Puzzle Board

      Wooden Puzzle Board with Drawers

      Portable Cardboard Puzzle Board

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      References

      1. ↑ https://youtu.be/VQnBz09EmgY?t=78
      2. ↑ https://youtu.be/VQnBz09EmgY?t=130
      3. ↑ https://youtu.be/VQnBz09EmgY?t=143
      4. ↑ https://youtu.be/VQnBz09EmgY?t=162
      5. ↑ https://youtu.be/QepDLZwbXmE?t=585
      6. ↑ https://youtu.be/VQnBz09EmgY?t=221
      7. ↑ https://youtu.be/sSJs2Gvn-qg?t=114
      8. ↑ https://youtu.be/sSJs2Gvn-qg?t=175
      9. ↑ https://youtu.be/sSJs2Gvn-qg?t=180
      1. ↑ https://youtu.be/sSJs2Gvn-qg?t=232
      2. ↑ https://youtu.be/sSJs2Gvn-qg?t=247
      3. ↑ https://youtu.be/sSJs2Gvn-qg?t=209
      4. ↑ https://youtu.be/sSJs2Gvn-qg?t=277
      5. ↑ https://youtu.be/v6O2c1oeikE?t=49
      6. ↑ https://youtu.be/zVhOkOkqa5I?t=180
      7. ↑ https://youtu.be/E4u3G4y-_QQ?t=39
      8. ↑ https://youtu.be/v6O2c1oeikE?t=377

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