Yes, 3d printers can be useful.

Yes, 3d printers can be useful. First time trying a puzzle-fit, and it worked great!

Files at http://www.thingiverse.com/thing:592463

Experienced all kinds of bugs: (1) an actual bug that got onto the hotbed crimp and fried it, (2) a Marlin firmware bug that prevents the filament from going forward (but still allowed retracts?), (3) filament bug: old brittle filament that broke or stripped, (4) hardware bug: worn filament gear + insufficient EZstruder tension.

What material did you use here?
Please follow up and let us know how it holds up in use.
Nice work BTW.

Printed in PLA. We’ll have to see how it stands up to the elements.