I have a love affair with wooden hinges and this challenge gave me the opportunity to go one step further with them. (It started some years ago when I came across the work of the late Tim Stead – in my opinion, a genius.) Accurately drilling the hinge pin hole in such a hinge is never easy, and those I planned for this box are 9.5” long and therefore impossible to drill. The following is an attempt to show how I overcame this bit of the challenge.
The first shot shows the oak blanks that were my starting point, along with my rough sketches done by the fireside the previous evening.
I used the box-joint jig that I ‘stole’ from Lumberjock Bob#2 to make the first cuts:
Then cut out the intermediate pieces on the small bandsaw:
Eventually, this was the result:
This was the clever bit (I thought)
After many calculations and sketches, I routed, at the appropriate depth and distance from the edge, a 3mm slot to take a cast-off knitting needle (!) hinge-pin. Knitting needles, typically plastic coated metal, are available in a range of sizes in .25mm increments. I have a good supply from my wife; a keen knitter.
..and filling of the gaps –
…resulting in –
Then, carefully trimming to my required size –
So, after an intensive day’s work / pleasure, I have, in effect, drilled two holes. I must be barmy as we say in Yorkshire!
The finished box is here
-- Res severa verum gaudium - True pleasure is a serious business. http://www.folksy.com/shops/TreeGems


































21 comments so far
TomFran
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2517 posts in 894 days
posted 682 days ago
Wow, Stewart, that was a great solution. As I read your introduction, I was wondering how you would “drill” those holes – but you were thinking “outside the box.” Nice!
I just hope your wife isn’t going to be looking for those knitting needles anytime soon ;^D
-- Tom, Surfside Beach, SC - Romans 8:28
CharlieM1958
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7697 posts in 1118 days
posted 682 days ago
You may be “balmy” Stewart, but the difference between a good woodworker and a great one is that the great one has the patience to spend a full day drilling two holes just right.
-- Charlie M. "Woodworking - patience = firewood"
GaryK
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9555 posts in 888 days
posted 682 days ago
Pretty cool, Yorkie. I like it!
-- Gary, East TX -- The longest journey begins with a single step.
CutNRun
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122 posts in 746 days
posted 682 days ago
I followed your pictures with interest. My box plans have been drawn up for some time, but our though processes are similar. I have a slightly different tack that I intend to take, but we’ll see how well it goes. I look forward to seeing the end product.
-- CutNRun - So much wood, so many trails, so little time
davidtheboxmaker
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372 posts in 705 days
posted 682 days ago
Neat idea.
Repeated use must lead to improved speed – if that’s important.
I bet this is going to be a great box.
jockmike2
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7368 posts in 1146 days
posted 682 days ago
Great illustration Mr. Stewart. Tom’s right it was good thinking. Just what is that you’re making there? lol mike
-- Mike. mwurm13@yahoo.com
YorkshireStewart
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784 posts in 801 days
posted 682 days ago
Thanks GentleJocks. All will be revealed over the next couple of days Mike.
-- Res severa verum gaudium - True pleasure is a serious business. http://www.folksy.com/shops/TreeGems
mot
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4904 posts in 936 days
posted 682 days ago
Thanks, Stewart, I’ve really come to look forward to your posts!
-- You can discover more about a person in an hour of play than in a year of conversation. (Plato)
toyguy
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726 posts in 737 days
posted 682 days ago
Sir Stewart of Yorkshire, you have done it again. Good post.
-- Brian's Table Top Toys http://home.mountaincable.net/~bgraham/
rikkor
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11335 posts in 774 days
posted 682 days ago
Ah Stewart, you are the man!
Paul
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607 posts in 992 days
posted 682 days ago
Ever since you posted your 2×4 entry, I’ve been waiting for “the other shoe to fall,” as they say. The first mighty “2×4” shoe came down and shook our lumberjock world – witness all the comments on your post!
I think I see the shadow of another very large “box” shoe coming down with a resounding thud to tumble whatever was left of our foundations (or at least mine).
This a wonderful, creative and challenging solution for executing a design feature!
Congratulations! Great mind power and crafting prowess!
-- Paul, Texas
mrtrim
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1698 posts in 780 days
posted 682 days ago
there will be another large thud when your wife finds out what you done with her needle !! lol
thanks for posting that stewart very informative
Russel
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2072 posts in 839 days
posted 682 days ago
Absolutely ingenious. Your creativity and resourcefulness are downright inspirational.
-- Working at Woodworking http://www.VillageLaneFurniture.com
Al Navas
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289 posts in 775 days
posted 682 days ago
Cool!
NOW I can make wooden hinges just like YOU, Stewart!!! Thanks for showing the way.
-- Al Navas, St Joseph, MO, http://sandal-woodsblog.com
Bob Babcock
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1808 posts in 986 days
posted 682 days ago
Just shaking my head….amazing….
-- Bob, Carver Massachusetts, Sawdust Maker http://www.capecodbaychallenge.org
CedarFreakCarl
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566 posts in 953 days
posted 682 days ago
Mr. Stewart, I would expect nothing less from a man of your woodworking genius! Now can we please see the @#$%^& box? lol. After the 2×4 chair, you’ve really got the old curiosity up…......
-- Carl Rast, Pelion, SC
Dick, & Barb Cain
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7050 posts in 1199 days
posted 680 days ago
Thank you for sharing.
Great process, now I’ll have to get my wife to start knitting, so I can steal her needles. LOL
-- -** You are never to old to set another goal or to dream a new dream ****************** Dick, & Barb Cain, Hibbing, MN. http://www.woodcarvingillustrated.com/gallery/member.php?uid=3627&protype=1
mrtrim
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1698 posts in 780 days
posted 680 days ago
miles125
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1443 posts in 905 days
posted 680 days ago
What do we have to do to get Mr Stewart Knighted? I’m just sayin…..
-- miles125, Alabama.."Architecture is frozen music""
mrtrim
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1698 posts in 780 days
posted 680 days ago
i guess a meeting of the l. j. roundtable
cheller
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249 posts in 1009 days
posted 680 days ago
Great solution, and very nice hinges.
-- Chelle http://artsgranddaughter.blogspot.com