MWP Sudoku Pieces

This project consists of the following two Easel files:

Easel File 1
Easel File 2

While identical bits are not required, it is suggested to use bits similar to those used to create the original Sudoku board. Those bits are:

1/8" shank, 30 degree V-bit
1/4" shank, 1/8" 2 flute downcut

This project contains specific directions to make the Sudoku pieces. An overview of the process can be seen in the attached video.

For this project, I used .225" MDF and the bits listed above. Use of a different material and/or bits may necessitate changing cut depths, feeds, and speeds.

The feeds and speeds in this project and its associated video (if published) are unique to my machine which has been stiffened in the X and Y axes, and has a Dewalt 611. Your machine may be different. Additionally, each machine is different and reacts differently.

You are responsible for using feeds and speeds appropriate to your machine. I take no responsibility for damage (material, bit, machine, or other) caused by using the values I provide.

Using multiple thin coats of spray paint, paint the material the desired color. Using a dark paint color on light wood or a light paint color on dark wood will provide a color contrast to make the numbers easier to see.

Due to the shallow engraving depths, the wasteboard must be square to the spindle. If it is not, the numbers will either engrave too deep (and chip out details) or too shallow (and lose visibility). If necessary, level the wasteboard using a technique similar to that starting at 9:05 in the attached YouTube video.

Apply double-sided tape to all areas on the material where the pieces will be cut out. This ensures that the pieces can be cut without tabs, yet will not move when being cut out of the material.

Peel the protective paper off the double-sided tape and affix the material to your wasteboard.

Using a 30 degree V-bit, home the bit on the lower left corner of the material and engrave the numbers into the material using Easel File 1 in Step 1.

Many factors can make the difference between a good cut and a rough cut or broken bit. They include machine modifications, bit size and type, and spindle speed. Always perform test cuts using the material and bit you are going to use before starting any project, and record your settings for future projects.

My machine has X and Y axis stiffness modifications, and a Dewalt 611. I used a 1/8 inch 30 degree V-bit on the engraving. The cut settings I used were .010" bit width, .035" full depth, .028" cut depth, 28 inches per minute, and Dewalt speed of 2.5.

Using a 1/8" 2 flute downcut bit, home the bit on the lower left corner of the material in the same place you homed the bit used in the previous step, and cut out the pieces from the material using Easel File 2 in Step 1.

Many factors can make the difference between a good cut and a rough cut or broken bit. They include machine modifications, bit size and type, and spindle speed. Always perform test cuts using the material and bit you are going to use before starting any project, and record your settings for future projects.

My machine has X and Y axis stiffness modifications, and a Dewalt 611. I used a 1/4 inch shank 1/8 inch 2 flute downcut bit to cut out the pieces. The cut settings I used were .0625" depth, 40 inches per minute, and Dewalt speed of 2.5.

Remove the pieces from the wasteboard and remove the double-sided tape from the back of each piece.

If necessary or if desired, sand the edges of the pieces. I chose to do this to remove the corners on the top and bottom, which made piece insertion into the Sudoku board a lot easier.

Using a spray finish of your choice, finish the top, bottom, and sides of all the pieces. This will prevent the paint from scratching or rubbing off, and will help protect the pieces.

These pieces were designed to be used with my Sudoku board. If you haven’t already made it, make the board by following the instructions in the MWP Sudoku Board project.