Tunneling

Tunneling is a common cigar burn issue where the inner filler tobacco burns faster than the outer wrapper and binder, creating a visible “tunnel” down the center of the cigar. This results in an uneven burn, poor smoke production, and a significant drop in flavor quality.

Tunneling can happen to even the best cigars if humidity levels, lighting technique, or puffing frequency aren’t properly managed.

cigar tunneling burn issue closeup

What Tunneling Looks Like

  • A cone-shaped cavity develops in the cigar core
  • The outer wrapper and binder remain unburned
  • The cigar may self-extinguish or burn unevenly
  • The flavor becomes flat or inconsistent
  • Ash falls prematurely and may appear ragged

“When tunneling happens, you're not tasting the full blend—just a hot, bitter core.”
— Cigar Aficionado – Troubleshooting Burn Issues

What Causes Tunneling?

1. Improper Lighting

  • Incomplete ignition of the wrapper
  • Using a soft flame or rushing the light-up
    Fix: Always toast the foot evenly and thoroughly before taking the first puff

2. Over-Humidification

  • Wrapper and binder retain more moisture than filler
  • Slows combustion of the outer layers
    Fix: Store cigars at 65–69% RH; use dry boxing if needed

3. Infrequent Puffing

  • Puffing too slowly causes wrapper to cool and extinguish
    Fix: Maintain a consistent pace—roughly 1 puff every 30–60 seconds

4. Poor Construction

  • Unevenly rolled filler or inconsistent tobacco distribution
    Fix: Choose premium cigars from trusted manufacturers with strict quality control

How to Fix a Tunneling Cigar

  1. Touch up the wrapper using a torch lighter
    • Aim the flame at the outer unburned wrapper, not the cherry
  2. Purge the cigar by blowing through it to clear stale smoke
  3. Trim the foot with a cutter to remove uneven edges
  4. Relight evenly while rotating the cigar slowly
  5. Increase puffing frequency slightly to balance burn rate

If tunneling persists, the cigar may be structurally flawed or too wet to recover fully.

Tunneling vs. Canoeing

Burn Issue Description Cause
Tunneling Core burns faster than wrapper Over-humidification, poor lighting
Canoeing One side of the wrapper burns faster than the other Wind, uneven light, user error

How to Prevent Tunneling

  • Light cigars slowly and evenly across the foot
  • Use a torch lighter for precision
  • Avoid smoking in high humidity environments
  • Don’t puff too infrequently or let the cigar rest too long
  • Dry box cigars that feel overly spongy or moist
  • Choose properly stored, premium cigars with good construction

Citation: Halfwheel – Diagnosing Cigar Burn Issues

Related Glossary Entries

Summary

Tunneling is both preventable and fixable, but it disrupts the balance, flavor, and performance of your cigar. Whether caused by user technique, storage issues, or construction flaws, understanding tunneling helps ensure every smoke is smooth, flavorful, and consistent from foot to nub.