Travel Humidor

Posted June 27, 2011

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A pull-apart box with a
silky-smooth fit.

By Suwat Phruksawan

I've had a lot of fun over the years building boxes of
all shapes and sizes.This one was made as a travel humidor
for a friend. The box can just as easily be used for a travel
jewelry box, eyeglasses—you name it.Whatever its use, the
real crowd pleaser is the silky smooth sliding action as the
box is opened: it always brings a smile.

I like working on small-scale projects. Materials are easy
to find and afford. (I get my best wood from my scrap pile).
Working on a small scale gives me a chance to do more
handwork than time normally allows on a large project.

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I sized this humidor to fit three Corona cigars.
If you aren’t a cigar person, just eliminate the humidifier
and Spanish cedar. Then,modify the box dimensions to fit
eyeglasses, pens and pencils, jewelry—anything that needs
to be contained while bouncing around in a backpack,
purse or suitcase.

Build the outer box from a single piece of Brazilian rosewood
that’s been resawn into thin boards. Size the pieces to fit the
objects you’ll be carrying.

Click any image to view a larger version.

Custom-fit the inner box by using the outer box as a form. Wax
paper prevents the boxes from sticking to each other and provides
the side clearance for a piston fit.

Remove the inner box from the outer box and line it with
Spanish cedar. Be sure to use water-resistant glue.

Drill air-escape holes in the end of the inner box.These holes
allow the boxes to slide smoothly past one another.

Build a Plexiglas humidifier to keep the cigars fresh.
Assemble the box with plastic adhesive.

Place wood blocks wrapped in wax paper inside the box.The
blocks support the walls when the inlay dadoes are cut and act as
a backer when the box is cut in two.

Lay out the inlays on the box after the lid is glued on.The
inlay on the humidifier end of the box (the end with the washer)
is 1/16" wider. The extra width will be removed when the
box is cut open.

Cut the grooves for the inlays.The groove in the top is extra deep
to allow for shaping the lid.

Install the inlays. Start with the top piece, then add the side
pieces. Fit the bottom inlay last, to minimize exposed end
grain.

Lay out the curve on the top with a piece of flexible steel.Hold the
steel at the center of the top and bend it to create the curve.

Plane and sand the gentle curve on the top.

Cut the box open with a single pass on the tablesaw.
Position the box so the blade is centered on the inner
glue-line of the wider inlay.

Extract the support blocks by drilling a hole at a slight
angle. Stop the drill and pull out the blocks.

Cut the recesses for the buttons with a brad point bit
then chisel them square.

To access the humidifier for recharging, pull the short
end of the outer box off the inner box and lift the
humidifier out of its compartment. The outer box has a rare
earth magnet embedded in one end. The outer box has a
washer glued to the inside of the short end.

This story originally appeared in American Woodworker April/May 2009, issue #141.