- Wooden cigar boxes are typically lined with cedar because this wood is the most suited to keeping the cigars at the right humidity level. Cedar also has a pleasant aroma. While the interior of the best cigar boxes are always lined with cedar, the exterior can be made from any hardwood. Common hardwoods include mahogany, redwood, spruce, walnut and oak. A wooden cigar box can be made completely from any one of these materials, or the inside of the box can be lined with cedar planks cut to the dimensions of the interior. They can be set into place with pegs, small staples or nails, or glued and clamped to the sides and bottom of the box with wood glue.
- Build the cigar box by first deciding on dimensions. Typically, cigar boxes are designed to fit a certain length and width of cigar. If you have a favorite cigar, measure its length to establish the width of your box. Then figure out how many cigars you want it to hold lengthwise and make this the length. Figure out how many rows of cigars you want it to hold and again multiply the cigar's width by this number to get the height of the box. You should allow about an inch on top for the cigars to breathe.
- Cut the hardwood to the measurements you have calculated with a table saw and miter attachment. Then rout out the corner joints using a corner joint bit and router. Assemble the box by dabbing wood glue on the connecting sides of the corner joints, and clamp the sides together to dry. Another method is to tack the sides together with small nails or staples.
- A cigar box is traditionally finished by sanding the top, sides and corners with 120-grit then 360-grit sand paper. Round the corners with sand paper by hand until you are satisfied with the look of the box. This brings the natural grains of the hardwood to the surface and prepares them for finishing. Using a hand-applied stain which is then hand-buffed with a rag gives a cigar box a natural, rustic feel, while applying stain with a brush gives it a designer finish and a sophisticated style.
