Somewhere around here is where my time over NewYears to work on this site has run out. For now just check the woodworking chapters in the "The Puzzling World of Polyhedral Dissections" book by Stewart Coffin [Coffin90].
But I give you a small hint I personally like designs which do not require any gluing the best, thus I try to make the various puzzle pieces out of one piece of wood if possible. Karin on the other hand seems not to have such inhibitons as you can see from her design of Karin's puzzle, which requires a lot of gluing.