A few months ago I was asked whether I could make 2 sets of stacking blocks- one set with a circular profile and the other with a square profile. At the same time I was asked by the same customer to make them a loose parts storage box (as shown on my Toys/Games web page).
This was probably one of the easiest commissions I have had, but I did have to work out a way to make sure the blocks were all uniform in size.
For the circular profile, I was able to buy several very nice pieces of clear pine dowel that was 35mm in diameter. Then I made a simple jig for the bandsaw that enabled me to cut them to the correct length. The set was made up of a total of 20 pieces, 2 of each length. The shortest started at 20mm, then they went up in 20mm increments to 200mm.
The square profile wasn’t quite as easy as there was not an appropriate sized square section available. Instead to get a 40mm square, I utilised 40x140mm clear pine and ripped it into 40x40mm sections on the table saw. Then I was able to utilise the arrangement I had made on the bandsaw to create the 6 lengths necessary for the set of 36 blocks (6 each at 40mm increments in length from 40mm to 240mm).
Sanding and rounding of sharp edges were the finishing touches.
Because these were a first (and also because the customer had commissioned the looses parts storage box) I priced them at only a few dollars above the cost of the materials. Having seen the price of sets like these from specialist wooden toy suppliers, I would increase that price for any future sales.