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Wooden Hinges #3: Retrofit - making the new hinge

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Blog entry by BritBoxmaker posted 585 days ago 1968 reads 1 time favorited 14 comments Add to Favorites Watch
« Part 2: Retrofit wooden hinges Part 3 of Wooden Hinges series Part 4: Retrofit - Preparing the way »

A busy day and that’s just making the hinge. First thing to do is cut up the material into four pieces.

then mark up the pieces, including where the slot is to be routed.

The next thing to do is route the pin slot. The pin is to be enclosed (not visible at the ends of the hinge). The hinge is 125 mm long, allowing 6 mm of un-routed material at each end, leaves a 113 mm long slot. To set the router table up for this I installed a 45 degree router bit, marked up one piece of the hinge for two points separated by 113 mm and aligned the tip of the bit on one mark and placed a block of scrap on the fence (attached by double sided tape), so

Repeating this for the other side. Then routed

Doing all four pieces. This shows one half of the hinge open and the other closed

In order to mark up and cut the hinge fingers the pieces were double sided taped together

and the slot routed edges masking taped together (masking tape underneath in this shot).

The fingers were marked up and the waste areas (cross hatched) removed on a scroll saw. Next to round off the outer piece edges. The inners don’t need to be rounded as the box lid cannot rotate inwards ( try looking at a solid metal butt hinge, you’ll see what I mean). These pieces only have one or two contact points so I double sided taped them to a longer, continuous, piece of MDF as a guide for routing.

Here’s the bit used, a 4.5 mm rounding bit.

The pieces together, complete with pin

and all together

Next I routed a 6 mm slot ( on the outside of the hinge) to take the piece thickness either side of the barrel of the hinge down to 6 mm ( the box wall thickness).

Then another 6 mm slot, 1mm further from the barrel, down to the spline width (you’ll see)

and routed the same slot on the inside, down to the spline width

Now the eagled eyed amongst you will probably be thinking ‘those barrel sides are only rounded on one side’. Correct. I don’t have a rounding bit that would do the other sides of the barrel so I routed a 45 degree slope along both sides (just shy of the existing round edges) and rounded these off with a file and sand paper to give this

Then I trimmed off the excess on the bandsaw giving

That’s the hinge made. Enough for me, today. Next time I fit the hinge in the box.

Be seeing you.

-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging. http://www.theartofboxes.com



14 comments so far

View michelletwo's profile

michelletwo

2232 posts in 1648 days


#1 posted 585 days ago

I rarely read blogs here on LJ’s. Don’t want to put radical ideas into my head!! :-) But I have been aware of your blog , and I have marveled at your willingness to break your train of thought & work to take pictures and then the time to do the blog. You are a woodworking/sharing gentleman of the first order. I hope folks take the time to thank you and tell you how much they appreciate your efforts.

-- We call the destruction of replaceable human made items vandalism, while the destruction of irreplaceable natural resources is called development.

View nomercadies's profile

nomercadies

502 posts in 971 days


#2 posted 585 days ago

This is like watching “The Brain Operation Channel” then thinking I can do an operation after watching one of the shows. I will continue watching and being mesmerized by the skills, but … I’m not thinking I will ever do an operation of this delicate nature. Thank you doctor.

-- Chance Four "Not Just a Second Chance"

View bigike's profile

bigike

4031 posts in 1921 days


#3 posted 585 days ago

Nice

-- Ike, Big Daddies Woodshop, http://www.icombadaniels@yahoo.com

View jaykaypur's profile

jaykaypur

3316 posts in 1040 days


#4 posted 585 days ago

Good job and look forward to the next step.

-- Use it up, Wear it out --------------- Make it do, Or do without!

View amagineer's profile

amagineer

1383 posts in 1229 days


#5 posted 585 days ago

You have conquered the hinge problem with flair.
-don

-- Flaws are only in the eye of the artisan!

View stefang's profile

stefang

12940 posts in 1967 days


#6 posted 585 days ago

This looks like excellent work Martyn and with some very precise routing work too. More importantly the hinges look understated and unobtrusive, which in most cases I prefer , although some decorative wooden hinges can be very nice too if they are not too bulky looking. Your blog is very clear and informative as well.

-- Mike, an American living in Norway.

View grizzman's profile

grizzman

6939 posts in 1936 days


#7 posted 585 days ago

very interesting, and i agree with mike, i am a fan of wooden hinges and of ways to use them and of different ways to incorporate them, im looking forward as to what will they be attached to…grizz

-- GRIZZMAN ...[''''']

View Sodabowski's profile

Sodabowski

2002 posts in 1465 days


#8 posted 585 days ago

Yet another great idea put to practice and shared with the mere mortals. Thanks Martyn :)

-- Holy scrap Barkman!

View littlecope's profile

littlecope

2898 posts in 2134 days


#9 posted 584 days ago

Nice Work Martyn!
Looking forward to the attachment…

-- Mike in Concord, NH---Unpleasant tasks are simply worthy challenges to improve skills.

View Kate's profile

Kate

396 posts in 2507 days


#10 posted 584 days ago

amazing
nicely done

-- Kate, http://www.wooden-box-maker.com

View gfadvm's profile

gfadvm

10737 posts in 1322 days


#11 posted 584 days ago

I can’t keep up with the process but you have given me some ideas for a new style wooden hinge. I love the whole clamshell design but got lost at the shaping/routing of the hinge ‘bases’. Not to worry though: it will undoubtedly make more sense to me when I see them mounted. Keep on keepin on!

-- " I'll try to be nicer, if you'll try to be smarter" gfadvm

View lanwater's profile

lanwater

3076 posts in 1566 days


#12 posted 584 days ago

All I can say is you are really resourcefull and overflow with ideas.

Thanks for sharing.

-- Abbas, Castro Valley, CA

View Roger's profile

Roger

14373 posts in 1436 days


#13 posted 584 days ago

Coming along nicely. The only thing I see that makes my hair stand up is that little piece and your fingers so close to that cutting bit. Please be careful.

-- Roger from KY. Work/Play/Travel Safe. Kentuk55@bellsouth.net

View jap's profile

jap

1226 posts in 686 days


#14 posted 584 days ago

cool

-- Joel

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