Thanks for the compliment!
This type of crossing-over puzzle wouldn’t work without doing the kerf adjustment. It has to fit snugly so that it won’t fall apart.
I haven’t yet found an economical way to do this, for printed puzzles (except for small puzzles under 5"). A copy of this one, which is cut from 10 sheets, will take around $60 in materials and a few hours labor, as I explain in more detail in a previous post.
Anyway… I don’t have a shop. If anybody is seriously interested in trying to make one, I don’t mind sharing the files. But it’s an exacting process. If you want to try out the technique for a small 5" puzzle, take a look at Part 1 of the tutorial.
If the picture were engraved, instead of made from paper prints, it would be much easier. The precision alignment problem would mostly go away. Hmm, maybe I’ll try doing one of those…