INSTRUCTION MANUAL for

Executive Cigar Humidor Kit #127570 77B43 10/07/97

Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686 © 1999 Woodcraft Supply Corp. “Helping You Make Wood Work” is a trademark of Woodcraft Supply Corp.

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Before You Begin Before beginning the assembly of your Woodcraft precut kit, read these instructions and become familiar with the parts list, drawings and photos which illustrate the text. We also recommend a dry assembly “practice run” on all parts prior to actual gluing. Instructions or information in bold print are critical for proper assembly and for avoiding irreversible assembly mistakes.

About Humidors The lining of our Humidor Kit is Spanish Cedar. This unique wood has a very low sap content and a faint spicy aroma (very unlike domestic aromatic, white, or red cedar). The lining should be sanded but not finished. The outside of the humidor can be finished with your favorite oil, urethane or varnish sealer. When you close your humidor it should create an airtight seal. The unique overlapping wedge joint of the liner in this kit will give you good results. An airtight seal allows you to control the humidity inside the humidor and keep the tobacco from drying out. A relative humidity of 60% to 80% should be maintained inside your humidor. You can create these humid conditions with the supplied humistat and monitor its performance with the hygrometer. After you have installed the humistat it will take about four weeks for the humidity to stabilize inside the box. The wood liner will be absorbing much of the initial moisture you put into the humidor. Be patient.

Important Notes About Solid Wood One of the unique characteristics of solid hardwood is the varying hues and patterns within a single piece of lumber. Since no two trees are identical, no two pieces of wood can be exactly alike either. Each has its own characteristics created by nature, not by man. Unlike plastics and some veneers in which the grain pattern is symmetrical, solid hardwood has irregular and asymmetrical graining, which adds to the overall beauty. In the same manner, the various shadings and colors within solid hardwood are part of its beauty.

Clamping Clamping is necessary to insure a tight accurate fit of glued joints. Conventional pipe or bar clamps can be used as well as band clamps. When dry fitting make sure you have sufficient clamps for equal pressure over all the joints before actually applying glue to the parts.

Glue We recommend Titebond II, water resistant, yellow aliphatic resin glue used according to the manufacturer’s instructions because the Humidor is exposed to moisture by way of the internal humidifier. Use a glue brush or cotton swab to spread the glue. A thin even spread on both parts is best. Clean up excess glue by scraping it off with a knife blade or scraper. Do not wipe glue off with a damp cloth as the moisture of the cloth will thin the glue and allow it to soak deeply into the wood. This will show in the final finish of your project.

Definitions Rabbet

Tools Needed •square •small screw driver •chisel •scrap wood block

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•pipe/bar/band clamps •Phillips screwdriver •X-Acto knife •CA Glue

• yellow, water-resistant, woodworking glue •scratch awl •mallet •glue brushes

Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686 © 1999 Woodcraft Supply Corp. “Helping You Make Wood Work” is a trademark of Woodcraft Supply Corp.

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Cigar Humidor Parts List Part Qty. Description Material Dimension T" x W" x L" 1 ......... 1 .................... Base Side, Right, w/pre-cut mortise .................................................. Alder ................................................. 5/8" x 43/4" x 101/4" 2 ......... 1 .................... Base Side, Left .................................................................................... Alder ................................................. 5/8" x 43/4" x 101/4" 3 ......... 1 .................... Base Front ........................................................................................... Alder ..................................................... 5/8" x 43/4" x 14" 4 ......... 1 .................... Base Back, w/pre-bored holes ........................................................... Alder ..................................................... 5/8" x 43/4" x 14" 5 ......... 1 .................... Top Side, Right, w/pre-drilled hole .................................................... Alder ................................................. 5/8" x 11/4" x 101/4" 6 ......... 1 .................... Top Side, Left ....................................................................................... Alder ................................................. 5/8" x 11/4" x 101/4" 7 ......... 1 .................... Top Front .............................................................................................. Alder ..................................................... 5/8" x 11/4" x 14" 8 ......... 1 .................... Top Back, w/pre-bored holes ............................................................. Alder ..................................................... 5/8" x 11/4" x 14" 9 ......... 1 .................... Mitered Frame Top-Pre Assembled ................................................... Alder ................................................... 3/4" x 105/8" x 14" 10 ....... 1 .................... Bottom .......................................................................................... Spanish Cedar ....................................... 1/4" x 135/8" x 101/4" 11 ....... 2 .................... Liner, Bottom Sides ..................................................................... Spanish Cedar ........................................ 1/4" x 43/4" x 815/16" 12 ....... 2 .................... Liner, Bottom Front/Back ........................................................... Spanish Cedar ..................................... 1/4" x 43/4" x 1213/16" 13 ....... 2 .................... Tray Supports .............................................................................. Spanish Cedar ............................................... 1/4" x 2" x 83/4" 14 ....... 1 .................... Slotted Tray Bottom, Base Side ................................................. Spanish Cedar ......................................... 3/8" x 81/2" x 113/4" 15 ....... 2 .................... Tray Sides .................................................................................... Spanish Cedar ............................................ 3/8" x 2" x 8-1/2" 16 ....... 2 .................... Tray Front/Back ........................................................................... Spanish Cedar ............................................. 3/8" x 2" x 121/8" 17 ....... 2 .................... Liner Top Sides ............................................................................ Spanish Cedar .................................... 1/4" x 113/16" x 815/16" 18 ....... 2 .................... Liner Top Front/Back .................................................................. Spanish Cedar ................................... 1/4" x 113/16" x 1213/16" 19 ....... 1 .................... Center Divider .............................................................................. Spanish Cedar ........................................... 3/8" x 15/8" x 81/8"

Hardware 20 ...... 1 .................... 55mm Surface Mount Humidor Hygrometer (127571) 21 ....... 2 .................... Cigar Keepers - Slim with Mounting Clip and Screw (127457) 22 ....... 2 .................... 10 MM Cylinder Hinges (27C11) 23 ....... 1 .................... Mortised Box Lid Support (16B34) 24 ...... 3’ ................... Grooved Type Keeper Strip Clear 25 ...... 1 .................... Bevelled Glass

Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686 © 1999 Woodcraft Supply Corp. “Helping You Make Wood Work” is a trademark of Woodcraft Supply Corp.

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Surface Preparation Humidor parts are factory sanded, but final finish sanding may be required according to personal preferences. If additional sanding is required, sand all parts prior to assembly. Sanding should be accomplished in a series of steps. Begin with a 180 medium grit paper and remove any scratches or blemishes. Final sanding should be accomplished with a 320 or 400 grit paper, removing the scratches left by previous coarser paper. Always sand with the grain of the wood. When you have finished sanding all parts, clean them of all dust by vacuuming or using a tack cloth. Take care not to deform crisp edges or profile lines if additional sanding is performed on this kit.

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Case Assembly Instructions 1. Assemble the humidor on a flat level surface. In a dry run, place the base sides (#1 and #2), front (#3) and back (#4) on edge, rabbet side down, and fit the machined joints together. Clamp this assembly together applying a medium amount of pressure, making sure that the end joints are fully seated and the edges are flush (Photo 1). When clamping be sure to put scrap blocks of wood between your clamp heads and the finished surface of the box, this will allow you to avoid marring the surface with the clamps. Check that the box is square by placing a try square in an inside corner of the box (Photo 2). When comfortable with the dry run procedure, glue the box base together in the order described below.

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2. Spread a thin layer of glue on the machined joints of all pieces. Clamp pieces together with a medium amount of pressure. Check for square with your try square. If the base is not square, loosen clamps and re-adjust. Set aside to dry. It is critical that the base of the box is square. 3. Repeat step 1 of the base dry assembly process using the top sides (#5 and #6), front (#7) and back (#8) (Photo 3). Clamp. Check for square. Proceed to next step. 4. Spread a thin layer of glue on the machined joints of all pieces. Clamp pieces together with a medium amount of pressure. Check for square with your try square. If the top is not square, loosen clamps and re-adjust. Set aside to dry. It is critical that the top of the box is square. 5. After the top assembly has dried, remove clamps and place on a flat level surface. Apply a thin film of glue on the top edges of the assembly (edges without hinge holes). Place the pre-assembled miter frame top (#9), with the routed profile up, on the assembly and position it so that all of the edges are flush. Apply clamps with a medium amount of pressure and let dry (Photo 4).

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Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686 © 1999 Woodcraft Supply Corp. “Helping You Make Wood Work” is a trademark of Woodcraft Supply Corp.

6. Dry fit the bottom (#10) in the rabbetted edges of the base “frame”. It’s all right if the bottom is slightly loose in the rabbet. Remove box bottom and place a thin film of glue on the inside of the rabbet. Place the box bottom in the rabbet edge and clamp with a medium amount of pressure (Photo 5). It is not critical that the bottom be square in the recess.

Finishing Only the exterior of the box and the inside surface where the box top and bottom meet needs to be finished. The Spanish Cedar lining will cover the remaining interior of the box. Lightly sand the exterior of the box in preparation for finishing. Use a sanding block and be careful not to round off corners.

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1. Remove any dust, which may have accumulated during the building process and final sanding by vacuuming or using a tack rag. 2. The wood may be stained or left natural. It should be sealed with a topcoat such as varnish, lacquer, polyurethane, or oil finish. If this is one of your first finishing projects and you are unsure how to proceed to get the effect you want, we suggest you obtain a copy of a good general book on wood finishing. Do not rush the finishing of your kit. Take your time, be very careful, experiment on scrap wood, and you will be rewarded with a truly handsome project.

Assembling the Cigar Trays, Cigar Tray Supports and Liner

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1. Place a thin film of glue on the rabbetted surfaces of the tray front and back (#16) and the tray sides (#15) and position them on the slotted tray bottom (#14). Apply clamps, apply a medium amount of pressure and let dry. Spot glue the center divider (#19) in the center of the cigar tray (Photo 6). 2. After the box is finished and thoroughly dried, you can insert the Spanish Cedar lining (parts # 11-12, 17-18). Dry fit the pieces in the top and base of the box (Photo 7). Do not force the liner pieces into place. If the pieces fit too tightly, lightly sand the ends until they fit snugly in place. 3. Once satisfied with the dry fit, remove the pieces and place a small drop or two of yellow glue on the backs of each piece and return them to their position in the box top and bottom. By spot gluing the cedar in the box, you will be able to replace the cedar lining as it ages and looses its aroma.

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4 . Spot glue the cigar tray supports (#13) on the interior sides of the base (photo #8).

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Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686 © 1999 Woodcraft Supply Corp. “Helping You Make Wood Work” is a trademark of Woodcraft Supply Corp.

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Installing the Beveled Glass 1. Because the glass keeper strip (#23) is flexible we found that inserting the strip in the frame and then cutting the strip to fit, as it is installed, is more accurate than measuring the interior of the frame and cutting pieces prior to insertion. Carefully place the beveled glass into the rabbetted frame. Start by cutting a 45° cut on one end of the keeper strip (Photo #9). With the glass in the rabbetted frame, insert the serrated edge of the keeper strip into the slot. Gently push the keeper strip in until it seats flush. Mark the proper length of the strip, remove from the groove and cut 45° at your mark. Continue this process around the frame. Using the flexible keeper strip makes it easy to remove the beveled glass for cleaning.

Mounting the Hardware 1. Place the two 10mm hinges (#21) in the holes at the back of the box taking care to position the leaves of the hinges perpendicular to the back of the box and the top of the barrels flush with the wood surface. This will ensure that the hinges open and close easily and do not bind (Photo #10). Using a very small screwdriver, tighten the screws of the hinges. By tightening the screws you will be expanding the barrel slightly so the hinge will be secured within the hole. No glue is needed to keep the hinges in place.

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2. Place the lid support (#22) into the mortise on the right side of the box base (Photo #11). Use a scratch awl to make starter holes through the support and into the side of the box. Secure in place with the provided mounting screws. Put a small drop of CA glue on and around the cylindrical stem of the stay and place it into the mating hole in the top of the lid. Let dry. 3. Place the hygrometer (#19) in the cigar tray in a convenient location so that you can read the dial through the beveled glass when the humidor is closed.

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4. Fill the Slim Cigar Keeper humidifiers (#20) according to the manufacture’s instructions. Place one in the base of the humidor and the other in the cigar tray.

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Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686 © 1999 Woodcraft Supply Corp. “Helping You Make Wood Work” is a trademark of Woodcraft Supply Corp.