How to Make a Wooden Cigar Box

Making the Pieces

• 1

  Select soft pine boards 3/8-inch thick available from a home improvement store or hobby shop. Choose four boards 8 inches wide and at least 12 inches long.

• 2

  Cut two pieces of pine 12 inches long for the top and side panels. Cut one piece 11-1/4 inches long for the bottom. Cut two pieces 7-1/2 inches long for the ends.

• 3

  Use a fine tooth blade on your table saw to cut the pieces to height. Cut the two long sides 3 inches wide. Cut the two end pieces 2-1/2 inches wide. Cut the bottom panel 7-1/2 inches wide. Leave the top panel full width.

• 4

  Set the table saw blade height to 1/4 inch. Adjust the fence to 1/8 from the fence. Start the saw and run one long edge of each long side over the blade. Use a push stick to feed the wood over the blade to keep your fingers back. Stop the saw and reset the fence to 1/2 inch from the blade. Run the pieces through the blade again. Reset the fence to 3/8 from the blade and run a third time to create a 3/8-inch wide, 1/4-inch deep groove.

• 5

  Sand the box pieces with 150-grit sandpaper. Sand all rough areas and lightly "break" or round over the edges.

Assembling the Box

• 6

  Apply wood glue to the short edges of the two end pieces. Fit the long edges to them, with the groove up, the outside ends even with the outside face of the end panels and the bottom edges flush with the bottom edge of the ends. Clamp them in place with small bar clamps, or quick clamps.

• 7

  Nail through the long side pieces into the edges of the end pieces with 1-inch finish brads and a tack hammer. Use two nails in each corner, one above and one below the clamps.

• 8

  Apply wood glue along the edges of the bottom panel and fit it into the open bottom face of the box. Nail through the long edges and end pieces into the edges of the bottom panel, three nails in each long edge, two nails in each end.

• 9

  Slide the top panel in from one end, above the shorter end pieces, so that the long edges ride in the grooves in the long sides. Open the box by sliding the lid to one side.

• 10

  Leave the clamps in place until the glue sets.