90 Days to Perfection
To build your PURO Humidor, a team of machinists, wood makers, polishers and inlay workers is used. Each humidor is painstakingly made by hand, utilizing a process which requires more than 100 man-hours.
Days 1 - 19
Each piece is precisely cut then stacked in alternating layers to allow for proper air circulation. This wood is dried and cured for 15 days. After the wood has cured, the wood makers cut and build each panel and wood frame piece to approximate size. Veneers are then applied using hot glue, a special sealing oil and a hydraulic press.
Day 20
The carpenters and wood polishers cut each piece of wood to exact size. The machinist chooses each piece of wood by hand, discarding any that is warped or does not have a precise veneer. All surfaces and edges of each piece are then planed and cut to the exact thickness and size needed. All moldings and joints are cut, with all holes for screws and wood doweling precisely placed. Each piece is hand-sanded until perfect in shape and size. The inlay workers now apply the Italian inlays to exact specifications.
Day 30
The carpenters and wood makers start to assemble your humidor by hand as the machinist make final cuttings of each piece to fit seamlessly. The entire humidor is then assembled to check for fit.
Day 35 - 59
The frame of your humidor is finished. Some of the smaller pieces and framework pieces are now machined to size. When these pieces are finished, the machinist starts to build the shipping box for your humidor. At this time, the wood makers adjust the fit of each humidor piece. They size each side panel, top, inlay, molding, front doors and drawers and cigar partitions in the drawers, as well as the the interior cedar pieces and interior drawers. Each piece of the humidor is squared and adjusted for a perfect fit and the holes for the hardware (hinges, locks and drawer pulls) are cut. The last adjustments for perfect fit of all pieces is done. The wood makers begin to fit the cigar tray drawer(s), interior shelves and the humidification system. Locks are placed on each drawer and the interior shelves or drawers are assembled and fitted into your humidor. When the entire humidor is completely assembled, each piece is adjusted for a perfect fit and seal, including the moldings and the molding strip to hold the glass top in place. After final adjustments are made, the entire humidor is disassembled and each piece of wood is hand-sanded with very fine sandpaper.
Days 60-69
The lacquer and polishing process begins by hand-sanding each piece. Once again, each piece of wood is given a final inspection for blemishes, which are removed or the wood piece is replaced. Your humidor then receives 4 coats of polyurethane lacquer applied in alternating layers of brush strokes (crisscrossing brush strokes for alternating layers). Each coat of lacquer takes 48 hours to dry. Between coats, each piece is hand sanded until it is "smooth as glass". Extremely fine sandpaper, steel wool and very fine abrasive cloths are used. After sanding each coat, each piece is cleaned, first with an air hose and then with a wet cloth, before returning to the paint room to apply the next coat of lacquer. A fifth coat of special finishing lacquer is applied by hand to obtain the final semi-gloss finish.
Days 70-74
Each piece is allowed to dry for 3 days, then shined and polished by hand.
At this time, your humidor is assembled by hand and all the brass fittings and locks are installed. The beveled glass top is installed and sealed. All drawers, cabinet drawers and other openings in the humidor are sealed with silicone to ensure a complete seal of the humidor. All drawers and door hinges are given final adjustment for a perfect fit.
Days 75-89
Now your humidor is completely assembled and finished and it is set aside for 15 days to allow the lacquer coats to completely set, and to also free the gasses from the lacquer coats before packing and shipping.
Day 90
Your humidor is ready to pack and ship.
