With the grid applied, flip the puzzle blank over and mount the face image. I used spray adhesive, but you could also brush on a thinned washcoat of white or yellow glue. Flatten the image with a J-roller or a piece of scrap wood wrapped in a towel. When the adhesive cures, spray aerosol shellac over the face to seal in the image and stiffen the paper fibers. It will help prevent tearout during the cutting stage. I applied three light coats. Trim the puzzle piece blank to its final size of 8″ x 10-1/2″ now.
Cutting Out the Pieces
Instead of cutting the puzzle pieces out one at a time, I sliced off a row of four from the larger blank and cut the row apart. Just bear in mind that it’s more important that your puzzle pieces have smooth, flowing edges than that they follow the pattern grid exactly. Keep the puzzle stock moving through the blade in one continuous operation, and don’t stop. Hesitation can lead to rough edges.