In particular, Tami Potter has designed a set of FREE DOWNLOADS that contain Crossword style letters that you can print out to fit in your one-inch grid squares. Here are some samples of finished products using the Crossword Puzzle concept:
The one above came from Tami Potter's website and I found the other two on Pinterest. This might be one of those rare occasions where it makes the most sense to use the 1" square punch as opposed to the traditional count and cut technique.
The alphabet downloads are scaled to fit on the one-inch squares and they are FREE with a purchase from the Snap-n-Crop Link to the right of this post on my blog.
Have you already made a puzzle mosaic? If yes, I would be honored if you would share it with me on my FB page: Minerva Mosaics with Tami Potter's Mosaic Moments