Wooden castle blocks

This is a set of wooden castle blocks made as a gift.

Wooden castle blocks

The inspiration was the set of wooden blocks from Down To Earth available here

Wood : Actually not sure. This was called "country wood" by the lumber people. An inexpensive wood. It was initially about 1.5 inches thick, that was smoothed in the lumber mill to about 1 inch thick.

Design : I made the gate, two towers and four wall pieces, drawn freehand. I made one entrance piece, two towers and four wall pieces. The towers and entrances required added supports to prevent them from toppling over easily.

Wooden castle blocks : The entrance with a door. Required Supports

Wooden castle blocks : The wall pieces 

Wooden castle blocks : Tower pieces : They required supports

Cutting : With a Skil Jigsaw.

Smoothing : Rounded over the edges with a rounding over bit on my router table.

Windows : Drilled a hole with a 9 mm bit and used a jigsaw to cut it out.

Supports. I rounded over a cuboid of the same wood and sliced off a small bit using the table saw. The two are supported with a screw inside, the head of the screw is covered with a plug of the same material.

Sanding : Very little needed on the surface. There were burn marks that hand to be sanded off for which I used a flexishaft with a sanding attachment.

Finish : Clear varnish wiped immediately after applying. There must be a better way to do this but I am learning this. If the finish comes off I will have to re apply this.

 Finished product: This can be rearranged to make a circle or a wall of castle.

Wooden castle blocks