This blog details how I made the hinges for my latest project, ‘56’ (also now used in ‘42’). In this blog I will be making one hinge, 56mm x 76mm x 6mm. I am using dissimilar woods for contrast. These are, in this case, sycamore and walnut. I work in millimetres. For those of you using inches there are 25.4 mm to the inch. There is a calculator in the pc you are using to read this blog, its not rocket science.
I cut four blanks 56mm x 42mm x 3mm, two of sycamore and two of walnut. The hinge pin is brass, 2mm diametre x 48mm long.

In this blog I will be using three router bits for all hinge machining.

First I cut the fingers of the hinge pieces, using the 6mm straight bit, cutting 6.5mm deep to allow the hinge to rotate just over the 90°.

In this picture the sycamore pieces are under the walnut ones . Both are cut at the same time allowing exact overlay. You choose the method you want to route these, there are many jigs available. Quite a few here on LJ’s.
I cut some 6mm MDF blanks at the same time to help with later operations.

Next stage is to route a slot on what will become the two inside faces of each hinge half. I used the 45° ‘V’ bit and the following setup.

The bit is set to cut 1.4mm deep, 3mm in from the rear guide. The two side pieces of MDF are stops, double sided taped to the guide to stop the bit 3mm from each end of the hinge piece. This means the hinge pin will not be visible on the completed hinge. I prefer it this way as a pin that doesn’t show doesn’t work it’s way out of the hinge over time. If you prefer a visible pin just leave the stops out and route over the full width of the hinge.



The MDF blank allows for cutting of the v slot without breakout on the hinge finger sides.

The pin locates in the V slot

and the other half covers it, much like a clam shell

The next thing to do is round off the outer edges of the hinge fingers, to allow hinge rotation. I used the third bit, a 3mm rounding bit – with bearing. and the following setup

The MDF blank aids in positioning and also stops breakout from the finger edges. The last operations are hinge assembly. For this size of work I use Viscous CA (superglue). Its quick and accurate. I’ll let the pictures tell the story




A little light cleaning up with 240 grit and theres your hinge.



Yes there is a gap between two of the fingers. I had thought to make another one but using this one serves to prove that I am not perfect and therefore only human like everyone else.
Be seeing you
-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging. http://www.theartofboxes.com

















22 comments so far
Greg The Cajun Box Sculptor
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3777 posts in 1478 days
#1 posted 430 days ago
Excellent tutorial Martyn. I really appreciate these hinges and the thought/design you put into them.
-- Every step of any project should be considered your masterpiece if you want the finished product to reflect the quality of your work. http://www.FineArtBoxes.com
Woodwrecker
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#2 posted 430 days ago
Excellent tutorial my friend.
Thank you very much.
I will favorite this one to use in the future.
Thank you again. Well done.
-- Eric
jeepturner
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896 posts in 962 days
#3 posted 430 days ago
Thanks for the blog Martyn.
Those area really nice hinges. The concept is brilliant in it’s simplicity.
I like the inclusion of the gap as evidence that you are “only human”, but I think I would need more proof. You make some amazing stuff. Thanks for sharing it with the rest of us mortals.
-- Mel
shipwright
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3392 posts in 968 days
#4 posted 430 days ago
Good tutorial Martyn. You make it all look so easy.
-- Paul M ..............If God wanted us to have fiberglass boats he would have given us fiberglass trees. http://prmdesigns.com/
stefang
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9472 posts in 1504 days
#5 posted 430 days ago
Good tutorial Martyn. This is wonderful technnique and I like that the hinge ends are hidden and also locked in. I would like to make some of these boxes with my grandkids. They would love the magical inside out effect. They can cut the box joints on the scroll saw and I can do the routing, or as an alternative I can show them how to to it with a sharp chisel instead. I really like this project a lot. Thanks for sharing it with us. I am only disappointed that there are no instructions in how to use the onboard calculator, lol.
-- Mike, American in Norway
Sodabowski
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1811 posts in 1003 days
#6 posted 430 days ago
Nice one Martyn :) Not rocket science but sure fine craft :)
-- Thomas - There is no such thing as a problem, there only are solutions.
SASmith
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#7 posted 430 days ago
Great blog.
Into the favorites.
-- Scott Smith, Southern Illinois
BarbS
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2181 posts in 2255 days
#8 posted 430 days ago
Thanks, Martyn!
-- http://barbsid.blogspot.com/
majeagle1
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#9 posted 430 days ago
Great blog Martyn, thanks for taking the time to do this !!!!
-- Gene, Majestic Eagle Woodworks, http://majesticeagleww.etsy.com/, http://www.flickr.com/photos/majesticeagle/
Randy63
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197 posts in 1062 days
#10 posted 430 days ago
Very good and well illustrated blog Martin. Thanks!
-- Randy, Oakdale, Ca.
patron
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#11 posted 430 days ago
excellent technique martin
love your curious and open mind
thanks for sharing
and clearing the path
-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle
eddie
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4595 posts in 784 days
#12 posted 430 days ago
thanks Martyn one of the better blogs explained well enough that even a newbe like me gets it .know you had to stop your other projects to help show this so thanks for the time to help your a good person and the last person who i knew was perfect they killed him.
-- Jesus Is Alright with me
KnotCurser
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1409 posts in 1238 days
#13 posted 430 days ago
Very cool – I will get around to trying this one. Promise!
Thanks teach – class dismissed!!
-bob
-- Man is a tool-using Animal. Nowhere do you find him without tools; without tools he is nothing, with tools he is all. - Thomas Carlyle http://www.ffrf.org
SisQMark
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353 posts in 770 days
#14 posted 430 days ago
Thank you for taking the time to show us another way to make hinges. Great tutorial Martin. Going in my favorites.
Mark~
-- Don't waste today, it is yesterdays tomorrow!~SisQMark
a1Jim
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87200 posts in 1747 days
#15 posted 430 days ago
Super blog and great idea,sorry it took me a while to comment but it took some time to try and consider the possibility your not perfect,I came to one conclusion… your must be fibbing to us. LOL your much much closer than I am when it comes to box making ,anther project exceptionally well done.
-- W James Brokenbourgh Custom furniture maker http://artisticwoodstudio.com/
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