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