We all make mistakes. Yes even me. I’ve been working on the design and build of a box for the best part of a month and a half now. You know I don’t like chunky boxes, the sort with way too thick walls. This box is about 125 mm square x 75 mm high. So I’ve made the wall thickness 6 mm, slightly on the thin side but not a problem for a shell or drop on lid box. Except this one has a wooden clam shell hinge (see first part of blog). This was a mistake
as the consternated look on the back of this box shows.
I tried to CA glue the broken pieces back in, to try and fix it, to no avail.
The weight of the box lid is too great for the size of hinge. The grain direction was also wrong.
Now its an anamorphic patterned, EZ Mitre box. A lot of design and build time went into it. I could have cried. I swore a lot, in several languages.
So I had a long think. One of my 3:00 am in the morning, long thinks. I came up with a new angle on what is basically an engineering approach (thank you MOD (DOD) training), retrofit hinges. This is the basic design
The top and bottom are 6 mm long, 2 mm hidden splines which will be buried in the box back (with 2 mm of back material on each side). Here the hinge is at various degrees of ‘opening’ seen from outside
The ‘meat’ of the hinge is 9 mm across and so much more substantial. The extra 3 mm of hinge will protrude from the back of the box. As its curved this should not look too inelegant. I’ll rescue the original 2 mm brass pin from the box as I will be cutting out material to give room for fitting the hinge as well as routing out slots for the splines to fit into. I’ll detail the make on the hinge as well. This is the type used for Pac Man, an earlier box.
To start I’ve cut and thickness sanded a piece of 4.5 mm Ebony
Cut into pieces 60 mm long
Re- arranged for correct grain direction for a wooden hinge
and glued up and drying, as I blog.
Are you sure Hank done it this way?
Thats all for now.
Be seeing you.
-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging. http://www.theartofboxes.com