After seeing shipwright’s nifty wooden box hinge technique , I knew I had to try it myself. I’m not sure if it’s been attempted on this large a scale, but I’m happy with how it came out. The only change I made to the original technique was putting the grooves on the face of the board instead of the edge, that way the somewhat-unsightly filled groove would be hidden from view on the outside of the tool chest. Here is the initial setup with the grooves still open:
I then filled in the grooves on the cottonwood rail piece and test-fit it with the lid on the tool chest carcass:
I haven’t yet filled the walnut top’s groove… that needs to happen after gluing in the rails, etc. The hinging action seems to be pretty smooth in my initial tests.
-- Allen, Colorado