Puzzle Chess Board

This project started innocently enough. Some people at my office wanted to know if I could print a chess set for them, and of course I said "Sure!". I looked around on here for chess boards and the puzzle ones really caught my eye.

Unfortunately, I wasn't really satisfied with any of the ones I saw. Some had pieces that were too loose, some were lacking uniform features on the top face, some were too small.

It was at that time that I decided that I'm just going to go build my own puzzle chess board (with blackjack...and hookers!). What I wound up with took ideas from several of the boards on this site, but with much tighter tolerances. The pieces fit together tightly enough that you can lift the whole board from the edge, but not so tightly that you need to hammer them together.

The end result (and what I posted here) is comprised of 30mm square pieces which are 5mm tall. The borders are 1.5x the piece height at 7.5mm, and they are 15mm wide. The full board will be 270m