Just finished watching UK kick Louisville to the side of the road and I'm happily puffing away on a Padron 1964 Monarca maduro to celebrate the occasion. It's time for another installment of the humidor build series....

I needed some specialty router bits so I headed over to Woodcraft in Lexington this morning and dumped a big bag of bucks on some Freud products. Got a spiral bit to cut open the box, a flush trim bit with bearings on the top and bottom both to trim the top and the edges of the box after I separate the lid, and a quadra-cut panel raising bit to use for various purposes to be determined. I reckon I spent enough on these three bits to buy a box of VERY good cigars. However, I never stint on tools and quality doesn't come cheap.

First thing off, I used the flush trim bit to trim the excess wood on the top piece back to near flush with the sides. After that operation I used fine sandpaper on a block to take the wood flush with the sides and get rid of the glue that slopped over. Dang! It's startin' to look almost like a box now! As you can see, there is a significant amount of piddly work involved in producing one of these things.

The most nerve wracking part of this whole operation is separating the lid from the box. At this point I have a lot of material and time invested and the whole thing could go right into the shi**er if I bobble this part. I'm still experimenting in the best way to handle this. I could just whack it off on the band saw but that leaves a rough edge on the parts that is a pain in the butt to sand down. This time I tried slicing the top most of the way off using the 1/8" spiral bit I bought this morning. I grooved the box most of the way through and will finish the job on the band saw. I'm still working this part out so it's a work in progress...and I'm still not overly thrilled with the results but I'm getting there.

Its lookin real sharp Ken!!

Now for the next hold-my-breath part...the trip through the bandsaw. The end parts are the problem here because the blade cuts through a piece of wood 8" long and 1/8" thick before hitting the thin stuff on the sides. A bobble here will screw the edges of the top and bottom beyond repair. Careful, careful! Then after I negotiate the length of the box I hit the other end with the long section of wood there. I just trust the machine to do its part while do mine....and it worked out fine.

If you look carefully at the second picture you'll see how the inside edge of the lid and bottom have a little rim of wood left. I used the flush trim bit to take that off and then started sanding carefully to even things up.

I know I keep saying it, but this is really looking great Ken.

I've got the edges worked down pretty good using 150 grit paper at this point. There's still work to be done to get the edges meshing properly and I'm still working on that process. The machines can get you close but the final fitting is all hand work. I'm at the point now where I can let the box rest for a bit while I start preparing Spanish cedar stock for the liner. I've got a rough 4/4 plank I'll start working with tomorrow afternoon after church. That process is similar to what has gone before with stock preparation but the fitting of the pieces is a picky operation...more to follow.

Very nice!!! I cant wait to see it done!
About how many cigars will that hold when it done???

That thing is a beauty already...

Keeps getting better.

thats beautiful. and i agree with quality tools being worth it especialy with projects like this. when are you talking orders anyways

Quotebilly82 - 3/31/2012  9:59 PM

Very nice!!! I cant wait to see it done!
About how many cigars will that hold when it done???

I'm not really sure. This is a test piece just to get a feel for the new equipment I've installed in the shop and to check out a few new techniques. The outside dimension is 9" x 12". The sides are .740 and the cedar liner will be about .250 so that will leave enough room inside for about 25 or 30 toro sized sticks, more or less.

Well now, Ain't that lovely.  

Lookin good man

This looks awesome Ken!

Ken, seriously, how much for you to build me a humidor?  Or, how much for me to be your apprentice?

OH VERY NICE!!!!

Really enjoying this thread Ken. Your craftsmanship is impeccable!!!:thumbsup:

Very nice Ken! I don't have as much experience as you but I have also found Freud to be a reliable product.