Woodworking duo's craft is more than a puzzle

By Cindy Posivio

Imagine a jigsaw puzzle made out of wood. A puzzle where each piece fits perfectly and carries the natural color and grain of the oak, cherry or other wood from which it came. Now add a craftsman with a skilled hand and an eye for precision to sand life-like features into each piece, turning the puzzle into a three-dimensional work of art. Sound impossible? That's what gary Kaufmann once thought as he paged through woodworking catalogs for new patterns Eventually, curiosity got the best of him, and he ordered a book with patterns for inlay wood projects, or intarsia.

He already had the scroll saw he needed to cut out the pattern pieces. He had taken up woodworking as a hobby a couple of years earlier, mostly making intricate doll furniture and other detailed cutouts for his own children. Starting with a simpler pattern, Kaufmann's first project was a teddy bear on a plaque. He made several more projects for his own family. Many saw his work on display at Gaylord's Farm and Home show last spring. A wooden eagle with a 36-inch wingspan made by Kaufmann was raffled off by the boy Scouts. Ducks Unlimited also auctioned off one of Kaufmann's pieces - a puppy with his chin on a duck decoy.

Phyllis Meffert joined Kaufmann in the hobby earlier this year. The two work together at the Lakeview Home. Kaufmann suggested Meffert give the art a try while she was recuperating from hand surgery in March. Knowing Meffert was already adept at using a scroll saw, kaufmann thought this was something she would be able to do. The partnership has blossomed into a hobby that keeps both of them as busy as they like.

Their work has taken the shape of angels, wolves, ducks, St. Francis of Assisi, roses, Indians and more. While the pair is not interested in developing a business, they do welcome orders to help finance their hobby.

Looking closely at the colors and grain, Kaufmann selects the pieces of wood for the projects. "It was the grain that gave the angel her hair and the bear his belly," he pointed out. Along with aspen, pine, cedar, black walnut, honey locust and other more common woods, the two have also used a few "mystery woods" they've found in scraps. "As you can see, scraps are very valuable to me," Kaufmann said.

After the wood has been selected, Meffert cuts the pieces out on her scroll saw. Some projects have had more than 100 pieces. Of the 50 completed projects, including thousands of pieces, there have only been five that didn't quite fit the first time.

"We've lost a couple," Meffert added. "The pieces make quite a few trips between our houses (just blocks away)." Once the pieces are cut, Kaufmann uses drum and finish sanders to add features to the to the wood. Hand sanding gives each piece its final touch. "The sanding is what brings them to life," Kaufmann explained.

After a clear coat has been applied to each piece, they are fitted together and glued onto a wooden backing. Three more clear coats protect the wood. Ranging in price from $35 to $150, many of the projects have been purchased as wedding gifts. Adding a newborn's name, birth date and vital statistics to a teddy bear's tummy also makes a novel baby shower gift.

"You can describe it all you want," Kaufmann said. "But until you see it, you can't imagine it."

Intarsia Times

Wood Magazine