Puzzle Disassembly

For puzzlers, there's nothing quite like the satisfaction of a fresh start, especially when tackling a used puzzle. To ensure the next puzzler gets the full, uncompromised experience, it's best to completely disassemble your puzzle before passing it on. Here is how to disassemble a puzzle properly to ensure the puzzle stays protected for years to come.

Completely Disassemble 

Completely disassemble a puzzle so the next puzzler can enjoy the full puzzling process. I have opened boxes of used puzzles to find them in various states of disassembly, such as:

• Almost Disassembled: A good effort was made, but many pieces were still interlocked.

• Factory Defects: Sometimes pieces were not completely cut during manufacturing, so they should be separated. I've seen this in puzzles that have been assembled many times; the previous puzzlers never took the time to fix the problem. If you encounter pieces that weren't fully cut during manufacturing, pull them apart carefully. If they're particularly stubborn, use a small, sharp craft knife to separate them, while using extreme caution to avoid damaging the puzzle face or your fingers. Resolving these issues ensures a smoother experience for the next person.

• Edges Packaged: Sometimes the puzzle is completely disassembled, but the edge pieces are kept separate in a small bag. This is not really a problem. You may think this is helpful, and means one less thing you need to do. If you don't appreciate the gesture, you can dump the edges into the pile, stir it up, and continue as usual.

• Large Sections: Sometimes puzzles have been disassembled into sections that or just small enough to fit into the box. This means the next puzzler has to disassemble the puzzle before beginning assembly.

• Small Sections: I've opened a used puzzle box to find numerous small plastic bags full of pieces. Each bag was labeled and contained the pieces that made up a specific detail of the puzzle, such as a barn, a car, a horse, a dragon, etc.

Reasons for Complete Disassembly

Although it might seem daunting to completely disassemble a puzzle after spending hours on it, there are several compelling reasons why this approach is generally preferred over keeping sections together:

• • Storage Efficiency: Puzzle manufacturers design their puzzle boxes to keep the loose puzzle pieces safely contained with just enough extra space so the pieces are protected during shipping and handling. Fully disassembling a puzzle allows it to be compactly boxed and stored as the manufacturer intended, which is particularly useful for those with limited space or large puzzle collections of puzzles.

  • Puzzle Longevity: Loose puzzle pieces can move freely in all directions, so they don't have undue pressure on any one area. Storing puzzles in large sections can strain the interlocking parts, potentially leading to damage. Completely disassembling the puzzle extends the puzzle's usable life.

  • Prevent Warping: Large, connected sections are more prone to warping, especially when under pressure or stored improperly. Disassembling the pieces minimizes this risk.

  • Uniform Usage: As puzzles are repeatedly assembled and completely disassembled, all pieces experience equal handling and wear. This prevents certain pieces or sections from fading or wearing out more than others.

  • Full Experience: Completely disassembling the puzzle preserves its challenge and appeal, making each assembly a fresh and engaging experience every time

How to Fully Disassemble a Puzzle

• • Start with Care:  Gently wipe the surface with a clean, dry, non-abrasive cloth. Begin disassembly by gently separating the pieces. Avoid forceful pulling or bending, especially with thinner puzzles, as this can damage the pieces. Avoid methods like rolling up puzzles and kneading them into pieces; this can stress the pieces and lead to fraying. The safest way is to gently separate the pieces, starting from the edges and moving inwards. Although this method is time-consuming and boring, it is needed for maintaining the puzzle's integrity and longevity

  • Box Repairs: Before placing the pieces into the box, check the box for damage, and tape any splitting edges to prevent further splitting.

  • Mix Thoroughly: Once all pieces are separated, combine them and mix them thoroughly. The aim is a completely randomized pile, ensuring the next puzzler receives the full challenge of finding every piece.

  • Dust and Debris: Before boxing your puzzle, ensure free from dust and debris. See the Puzzle Dust article for cleaning tips.

  • Missing Pieces: Ensure all puzzle pieces are accounted for. It can be incredibly frustrating to revisit a puzzle only to discover pieces are missing. Look under the table you were working on and the surrounding area before putting the lid on your puzzle box.

  • Sorting: If you are keeping the puzzle for your own use, you may also want to consider sorting the puzzle as you dismantle it. Some puzzle enthusiasts like to sort their pieces for easier assembly next time. You can sort by edge pieces, interior pieces, or even by color or theme. This is not a good choice if the puzzle is to be sold, gifted, or donated.

  • Proper Storage: Place all the disassembled pieces back into the original puzzle box. For additional protection during storage, you can place the pieces into a large plastic bag that allows the pieces to move freely or include a desiccant packet.

Final Thoughts

By taking the time to fully disassemble your puzzle, you're not just preparing it for storage; you're offering the gift of a complete and unhindered puzzling adventure to the next person who picks it up. It's a small gesture that makes a big difference in the world of puzzling.