Stickman No. 3 Puzzleboxes contain
Robert’s first crafted wooden gears, which
proved to be a huge challenge on a radial
arm saw. No two gears were exactly
identical and most had to be meticulously
sanded by hand to properly mesh. Robert
used wax, which turned shiny where gear
teeth would pinch to determine points that
required sanding. These gears were so
time consuming, that Robert enlisted the
help of a friend who after experiencing the
same frustration subsequently dubbed this
design as “the devil’s baby”.
Getting the tension perfect on these
boxes was a challenge, and to ensure gear assemblies locked in place before rotating, cardstock spacers
were put under some gears to produce the proper amount of friction. On all early designs, Robert used a logo stamp carved from the cap end of a metal pipe and hammered
his hallmark into each box. On some puzzles, this mark turned
out faint, and this stamp was retired after the Stickman No. 3. All
future puzzles had their limited edition numbe

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