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Greene inspired Night Stand #16: Door glueup and Brusso knife hinges

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Blog entry by ChicoWoodnut posted 2122 days ago 2631 reads 0 times favorited 13 comments Add to Favorites Watch
« Part 15: Blacker indent summary - Lots of sanding on this detail Part 16 of Greene inspired Night Stand series Part 17: Glue up + fitting and hanging doors »

I glued up the doors and set in knife hinges this week. Here are a few photos of the process.

First I glued up the doors. I sometimes have problems getting my panels and doors to glue up square so I came up with this simple jig to help with the process. It is nothing more than a couple of jointed sticks clamped square to the bench to keep the assembly square.

Once I have the jig all square and secure I put two strips underneath to keep the sqeeze out from making a mess of the panel.

Put on some glue.

and clamper up.

The jig keeps everything square and all it really is is some jointed sticks. Perfect!

So then I set the knife hinges into the top and bottom rails in the door opening. Here I am measuring the bottom rail (the one with the bottom glued on to a rabbet). the hinge sits back 1/4” from the front and 1/16” from the edge of the tenon. The tape was intended to keep the router from blowing out the front (more on that later)

Then I routed between the lines with a 1/4” straight bit.

It still blew out on the tenon side :(

Then I chiseled out the waste to the line.

Here is the hinge in place.

On the top rail I tried another idea. I thought if I cut in the front of the mortise with my little hack saw blade it might not blow out.

It still blew out on the tenon side only this time it was a little worse, because the blowout started at the back of the saw kerf. Dohhhh :(

So I’m thinking that it was really unreasonable for me to think that I could get away with leaving a little 1/16” sliver over on that side. I will just trim it out with a chisel and leave a little gap. I don’t think it really looks bad. Here is the case with the knife hinges installed. I still need to mortise hinges in the doors tomorrow after the glue up sets. I’ll post more pictures then.

UPDATE

I got four perfect ones on the second nightstand. The secret is start on the inside and come out very very (very) slowly with the router bit. I wonder whose side of the bed this one will go on. Hmmmmm.

-- Scott - Chico California http://chicowoodnut.home.comcast.net



13 comments so far

View Todd A. Clippinger's profile

Todd A. Clippinger

8699 posts in 2601 days


#1 posted 2122 days ago

I have been looking forward to each of these posts. I just love the Greene & Greene style.

Thanks!

-- Todd A. Clippinger, Montana, http://americancraftsmanworkshop.com

View abie's profile

abie

550 posts in 2272 days


#2 posted 2122 days ago

scott:
Great job I love the way you give us pictures of the process.
I’ve been trying to do the same with my project but can’t get the pictures to post
maybe later.
My project is almost done and I will post those pictures soon.
the smoke here is so thick I can’t even see the sun..
Glad the Humbolt fire is out.
Bruce

-- Bruce. a mind is like a book it is only useful when open.

View gizmodyne's profile

gizmodyne

1763 posts in 2592 days


#3 posted 2122 days ago

Great post. I have never tackled hinges like those.

I wonder if you just routed the rectangle and finished the front edge with chisel if you would avoid the blowout.

-- -John "Do I have to keep typing a smiley? Just assume it's a joke." www.flickr.com/photos/gizmodyne

View ChicoWoodnut's profile

ChicoWoodnut

904 posts in 2317 days


#4 posted 2122 days ago

I thought the same thing gizmodyne. Fact is that 1/16” is a pretty slim sliver. I think next time I will leave the exit part until the rail is glued into the case then finish it off with a chisel. That way the glue might keep it supported. I have only done the first case. I still have one left to try out that theory. I really like these hinges and will likely use them again.

-- Scott - Chico California http://chicowoodnut.home.comcast.net

View gizmodyne's profile

gizmodyne

1763 posts in 2592 days


#5 posted 2122 days ago

My other idea is to do the round over after, clamp a piece of stock to the one you are routing to a)support the router b)back up the workpiece to minimize tearout. Then do the round over.

-- -John "Do I have to keep typing a smiley? Just assume it's a joke." www.flickr.com/photos/gizmodyne

View Chris 's profile

Chris

1865 posts in 2493 days


#6 posted 2122 days ago

Nice work…. I look forward to seeing the rest.

-- "Everything that is great and inspiring is created by the individual who labors in freedom" -- Albert Einstein

View Bob #2's profile

Bob #2

3808 posts in 2523 days


#7 posted 2122 days ago

Great series Chico.
I saw that blow out on the endgrain and I wonder if you could run some cyanoacrylate on that end before you routed the latch inset?
I don’t know but just thinking out loud.

Bob

-- A mind, like a home, is furnished by its owner

View ChicoWoodnut's profile

ChicoWoodnut

904 posts in 2317 days


#8 posted 2122 days ago

Thanks Bob, I do that a lot (thinking out loud).

I did the second night stand and added pictures above. All four hinge motises (Morti?) came out perfetly this time. The trick was to start on the inside and come out the front very slowly with the router. I may adjust this technique on some future project by not leaving the sliver at all thus creating a zero gap door. Hmm. Zero gap sounds intreaguing.

-- Scott - Chico California http://chicowoodnut.home.comcast.net

View Dorje's profile

Dorje

1763 posts in 2498 days


#9 posted 2122 days ago

Nice work! That router looks like a monster tackling that fine little mortise job…might be time for the little one…

-- Dorje (pronounced "door-jay"), Seattle, WA

View ChicoWoodnut's profile

ChicoWoodnut

904 posts in 2317 days


#10 posted 2122 days ago

Well dorje. There is nothing like hearing the obvious and being surprised by it. that is the best suggestion yet.

I was hoping my kids and lovely wife would pool resources and buy me a colt for fathers day. I kept dropping hints. Abigail, my 19 year old daughter said I didn’t need two routers. (She wants to get her MBA and be a CFO or something)

Wahhhhhhhh

-- Scott - Chico California http://chicowoodnut.home.comcast.net

View Grumpy's profile

Grumpy

19074 posts in 2353 days


#11 posted 2121 days ago

Great blog Scott.

-- Grumpy - "Always look on the bright side of life"- Monty Python

View abie's profile

abie

550 posts in 2272 days


#12 posted 2121 days ago

Scott:
Nicely done. still want to post my project Gamble entry table to the web but can’t quite figure out the blog protocall’s yet.
CA glue is great stuff for fixing blow outs.
I used it on my bread board which came out nice.. You cannot see where it was applied…
BT

-- Bruce. a mind is like a book it is only useful when open.

View Dorje's profile

Dorje

1763 posts in 2498 days


#13 posted 2121 days ago

”Abigail, my 19 year old daughter said I didn’t need two routers.”

Well one’s a router, the other is a laminate trimmer. Very, very different… ;)

-- Dorje (pronounced "door-jay"), Seattle, WA

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