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By
KONRAD SAUER,
Photography By DAVE STARRETT |
HUMIDOR
(part 2) |
 |
| Walnut
splines and edge inlays contrast beautifully with
the dark markings in the spalted maple |
|
The edges
of the outer box get a decorative inlay. Before you balk at
the apparent difficulty of inlaying a contrasting wood on the
edges of your box be assured that this is nothing more than
a strip of wood inserted in a rabbet that is as deep as it is
wide. Cut the rabbets on the tablesaw and fill them with more
black walnut. Start with the top and bottom inlay pieces, mitring
the corners as you go. Adhere the walnut strips with PVA glue
and clamp in position with masking tape. When the top and bottom
edges are done fill in the corner edges. Once the glue is dry
use a block plane with a very fine mouth to plane the inlay
strips flush.
When the outer box is finished cut the lid off using a tablesaw.
Once the lid is separated from the box, smooth the cut edges
with a scraper.
The Cedar Lining
 Use polyurethane
glue to edge-join the 3"-wide strips of Spanish cedar together
to get wide enough blanks for the inner lining. After planing
the glued-up blanks smooth, proceed with cutting the lining
pieces to size. The entire box lining is pressure-fit except
for the last two short pieces. These get a bit of glue along
their bottom edges. Pressure fitting the lining allows the sides
to move with changes in humidity. Fit the bottom first, then
the long sides and finally the short sides. Leave the top edge
1/4" proud to act as the seal with the top of the box. Use a
plane to take a bit off the top edge allowing the box to close
without restriction.
Finishing Touches
| Spalted Maple |
If
you've ever cut and split maple firewood from
less-than-vibrant trees, spalting isn't new to
you. It's one of the first stages of wood decay,
but if the process is arrested early enough the
random pattern of dark brown squiggles left by
the spalting moulds can be quite striking, and
the wood will still be structurally sound. Many
woods can develop spalting if exposed to the right
conditions during storage, but maple is especially
prone to it because it's rich in natural sugars
and low in tannins that restrict microbial activity.
Although spalted lumber is often the product of
accidental neglect, the effect can be created
intentionally. Spalting moulds are everywhere
and thrive best under conditions ranging from
20% to 28% moisture content and a temperature
range of 10°C to 32°C.
To spalt small pieces of maple, soak them in water,
place the wood in a tightly-sealed plastic bag,
then stash the bundle in a dark place that's about
20°C. Periodically check on the progress of the
microbes and dry the lumber when several passes
with a sharp hand plane reveals the look you're
after. --Steve Maxwell |
|
With the
lid placed onto the box, mark the positions of the hinges. Drill
out the pockets required for the quadrant hinges' travel arms
and pare to final shape using a sharp chisel.
To
dress the box use a smoothing plane set very fine to take off
any high spots. Finally, install the humidifying puck and hygrometer
which distinguishes the box as a humidor.
Finish the humidor with three coats of rubbed-out polyurethane,
sanding with 600-grit wet/dry sandpaper between coats. Follow
the poly with a coat of wax over the entire box.
I can't wait until I find my next piece of spalted maple. That
will be cause for celebration--maybe even a good cigar! |
| You
will need: |
| For
outer box |
Material |
Size |
Qty |
| Top
and bottom |
spalted
maple |
7/16"
x 8 3/4" x 11 3/4" |
2 |
| Front
and back |
spalted
maple |
7/16"
x 5 1/4" x 12" |
2 |
| Sides |
spalted
maple |
7/16"
x 5 1/4" x 9" |
2 |
| Edge
inlay |
black
walnut |
3/16"
x 3/16" x 10"* |
1 |
| Splines |
black
walnut |
blade
kerf x 5/16" x 20"* |
1 |
| Lining |
| Top
and bottom |
Spanish
cedar |
1/4"
x 8" x 11" |
2 |
| Lower
front, back |
Spanish
cedar |
1/4"
x 3" x 11 1/8" |
2 |
| Lower
sides |
Spanish
cedar |
1/4"
x 3" x 7 5/8" |
2 |
| Upper
front, back |
Spanish
cedar |
1/4"
x 9/16" x 11 1/8" |
2 |
| Upper
sides |
Spanish
cedar |
1/4"
x 9/16" x 7 5/8" |
2 |
| Hardware |
| Quadrant
hinges |
brass |
Lee
Valley 00F10.13 |
2 |
| Humidifying
puck |
Bear
Woods Supply Co. QC-1 |
1 |
| Hygrometer |
Lee
Valley 46K50.02 |
1 |
| *
cut to length |
|
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