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Cigar Boxes
Steven Ragatz explains plans
to build humidor
Home-made humidors? Cigar boxes
are the easiest of the standard juggling props to
build your-self. I think they are even easier than
making bean bags - that is - ROUND bean bags...
I build my own boxes. You can use
expensive plywood if you want to get fancy, but I
have always used wall paneling. This is the stuff
with the imitation wood grain printed on one side.
Often the pattern will include grooves to simulate
wood planks. This usually means that there is lots
of waste material. Still, one 4x8 sheet costs
about $15.00 American and will make three or four
sets of boxes (12-16). Check your local hardware
store. You will want paneling that is multi ply.
Don!t buy fiber board, compressed board, luan, or
particle board. None of these work well. Look for
a middle weight. Some of the really thin sheets
can make some really nice light weight boxes and
heavier weights make sturdier boxes. I like mine
in the middle ground. Pick an interesting pattern.
You can get all sorts of colors, wood grains -
even brick! <- Juggling bricks look pretty
good!
Basically, you build a box. I
don!t remember the exact measurements that I use
but they are aprox. 5 X 7 1/2 X 2 3/4 inches. You
will need to cut side panels, edge panels and end
panels. The edge panels overlap the side panels
but not the ends. That is because you need to
subtract the width of the stock from the total
length. If you use 3/16 inch. ply then the
dimensions for each side panel is 4 5/8 x 7 1/8.
The edge panels are 2 3/4 X 7 1/8. The end panels
remain 2 3/4 X 5. The end panels cap on the sides
so that when the corners of the box become
rounded, you can just pop the ends off and replace
them without having to completely rebuild a new
box.
The panels:
_______
|_______________________|
I
I
I
I I
I
I
I <--- side
panels
I
I
I
I
I
I
|
|
|
|
|
_______ <----------*Note
overlap*----------->
|_______________________|
^
^
|-------------------------------- edge panels
--------------------------|
You can use the undesirable side
(i.e. scrap) for the end panels because they will
be covered with suede.
Your best bet for this job is to
use a table saw. Cut all of the length for the
edge and end panels with the same saw blade
setting. This helps the fit when you assemble.
If a saw is not available then
you will have to cut them by hand. The light
weight paneling can be cut with a heavy duty craft
knife and some elbow grease. It is important to
keep each piece square. Once all the pieces are
cut, sand them so that they all size with each
other and are relatively square.
I use 1/2 inch. square pine stock
for the frame. Scrap lumber works well if it is
light weight and small (1/2 X 1/2 or so). Cut
lengths the length of each side panel. Also cut
pieces the width of the side panel minus the width
of the pine frame stock. You need to make a frame
that is the same size as the side panels. Butt
joint the ends - don!t miter them. The frame
pieces go right on the edge one the wrong side of
the side panels.
The Frame:
FFFFFFFFFFFFFFFFFFFF
f
f
f
f
F: 1/2 X 1/2 stock the length of one side panel.
f
f
f: 1/2 X 1/2 stock the width of one side panel
f
f
minus 1 inch.
FFFFFFFFFFFFFFFFFFFF
Apply wood glue and let dry.
After the glue has set, use heavy staples or small
brads to reinforce the joint. Next stick on the
edge panels using glue and staples. These overlap
both the frame and the edges of the side panels.
Square up the box before the glue sets. Finally,
glue and staple the ends. Make sure that the box
is square before you stick on the first end. Up
until this point, square-ness has not been very
important. You will make the box square once the
first end is stapled.
Lightly sand all edges. I use
carpet tape (two sided) and stick on suede ends
cut the same size as the end panels. Electric tap
over all of the edges to keep splinters from
sticking.
These boxes cost very little and
are very strong. I accidentally ran over one with
my car once and only cracked the side panel. All
of the joints held.
No longer will I tolerate rounded
corners! Ha! This box has a dirty spot - THROW IT
OUT! Prop boy!! Get me a NEW BO X!
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