Turning a Cigar Box into a Fly Box

Three cigar boxes that I have modified and turned into fly boxes.

The contents of the three boxes from above.

Fly fishermen are notorious tinkerers.  Nothing is ever good enough for an avid fly fisherman.  Flies could be tied slightly different which might trigger more bites.  A different fly line on a rod might make the rod load better and cast further.  On a slow day, a fly fisherman might try the same fly for twenty minutes and have a different retrieve for every cast.  We always want things to work better, to look cooler, and to be more productive.  I think this moniker is both deserved and appropriate in most cases.

There is another stereotype that seems to be applied to fly fishermen as well.  It is assumed by many (incorrectly I might add) that fly fishermen are older wealthy gentlemen and that it costs a small fortune to purchase all the necessary gear to get started fly fishing.  Admittedly, I am not a rich man…at least in terms of money.  I don’t have thousands to sink into a Clackacraft drift boat, or eight hundred dollars to sink into a brand new Orvis Helios 2 outfit.  I do however have the desire and time to make the things I want but cannot splurge for.  The project I am going to outline today is a great example of a shortcut that any normal person can take if they want a beautiful and unique fly box.  Granted, it will not be made out of aircraft grade aluminum with fancy latching windows that are spring loaded, but it will become uniquely yours and cost a fraction of the price.

To get started, you need to make a trip to a local tobacco or cigar store because you are going to need an empty cigar box.  I buy mine from a cigar store that sells old boxes for two dollars apiece and all the proceeds go to charity.  The first time I attempted this project I was surprised and impressed at how sturdy and beautiful these boxes are.  The hinges, clasps, and wood are attractive and strong.  Usually, you can be as picky as you want when it comes to selecting just the right box too.  Widths, depths, and lengths will vary greatly so you might want to think about the application for the fly box prior to selecting a box.  Are you going to put a couple hundred size 12 Adams’ in the box or a couple dozen deer hair mice?

A cigar box I picked up for a couple of bucks.

After you’ve purchased the box, you will need to purchase the foam that will line the inside of the box.  I buy mine from Michael’s and Jo-Ann’s fabrics.  I am partial to white sheets that are six millimeters thick since the two millimeter thick sheets make it more difficult to get a hook into and are more likely to allow a fly to come loose.  I’ve always stuck with the white foam since the colors of the flies will stand out more but I am going to give the black sheets a try one day just to see what they look like.

You can see the difference between the two millimeter (on the left) and six millimeter thick foam (on the right).

Next, you are going to need to decide if you want to keep the box with its original appearance or if you want to give it some color and customize it a little bit.  Some of the boxes have a unique and cool look to them but I have recently went back to all of my boxes and given them a coat of spray paint.  This allows you to color code your fly boxes, make them look more professionally made, and makes any stickers really stand out if you want to give them some decoration.  If you are going to paint them, I suggest spray paint and also that you paint them before moving on to another step.  You run the risk of spray paint getting on the foam if you paint the box after completion.  If is also up to you if you spray paint the inside, the outside, or both.

This was a cigar box that got a coat of black spray paint.

Now you’re down to the last step.  You need to accurately measure the inside of the cigar box both length and width.  You will then mark those dimensions on the piece of foam and cut the foam to fit.  I like to use a razor and a straight edge like a ruler in order to make sure I get the straightest cut.  Scissors have a tendency to get off track slightly and imperfections will be visible when construction is complete.  You also need to decide if you are going to attach foam to the inside of the lid as well.  I usually do because I want to store as many flies as possible.  You will want to keep an eye out however to see how the lower part of the box and the inner lid interlock with one another.  You might need to cut the foam slightly smaller than the inside of the lid to ensure the box can close.  As far as attaching the pieces of foam are attached to the box, I like to use a strong adhesive such as Goop or epoxy.  Sometimes the foam wants to bubble up while the adhesive dries so you might want to place a weight on top of the foam to ensure that it lies flat.  Finally, if you are going to put some larger flies in the box, you might consider cutting some slits in the foam with a razor and straight edge.  This way flies can be wedged into the foam rather than inserting the hooks into the foam which will slowly deteriorate the foam over time.

A nearly complete fly box.  Wedges were cut into the foam to reduce wear and tear.

This is the top of the box that needed some gaps between the edge of the box and the edge of the foam.  This makes sure that the box will close and gives it a snug fit and shuts securely.

If you look closely, you can see these large flies are wedged in the grooves and not hooked into the foam.

And that’s it.  All you need are some cheap materials, some time, and some proper planning and you have a fly box that is as nice as one you can buy in a fly shop.  Even more, this fly box means more because YOU made it and things that are built with our own hands seem to carry more prestige…at least in my opinion.  They also make great gifts for friends or family members and great Christmas presents.  Speaking of Christmas, you can do the same thing with a gift card tin and end up with a pocket-sized fly box.  Anyway, good luck and let me know if you have any questions or need any help with any part of the assembly.

One of my favorite boxes that I engraved with a wood burning tool.
I actually picked this box up at Michael's for five bucks but didn't have to spray paint it or remove any stickers.

The contents of the box shown above.  This is primarily my mousing box but has some other bass flies as well.