Holy cow!

Do you calculate in advance (after designing) how many of each size part will be needed and then go about manufacturing all the parts before you start construction or is the process more casual?

Michael,

The only thing I planned was the original 2"x2" grid pattern. Everything else is designed on the fly. Once I figure out the design I want, I go ahead and start rough cutting the pieces. For example, there are 100 little flowers and each one has 16 pieces that is one size, thus 1600, and 8 pieces of another, thus 800. Once cut, I chisel the angles on each end. The angles that I work with in this design are, 45, 22.5 and 67.5. If your grid is square, all of the pieces should fit like a puzzle, if not, you make very small modification to the pieces that don't fit. Lots of repetitive work. Make sure your chisel is super sharp.

Cheers,

JC