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.



































21 comments so far
TomFran
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2329 posts in 382 days
posted 170 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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3497 posts in 606 days
posted 170 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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8182 posts in 376 days
posted 170 days ago
Pretty cool, Yorkie. I like it!
-- Gary, East TX -- The longest journey begins with a single step.
CutNRun
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69 posts in 234 days
posted 170 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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248 posts in 193 days
posted 170 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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3814 posts in 635 days
posted 170 days ago
Great illustration Mr. Stewart. Tom’s right it was good thinking. Just what is that you’re making there? lol mike
-- Mike. Profisher50@yahoo.com
YorkshireStewart
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570 posts in 289 days
posted 170 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.
mot
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4830 posts in 424 days
posted 170 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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397 posts in 225 days
posted 170 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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6455 posts in 262 days
posted 170 days ago
Ah Stewart, you are the man!
-- Maplewood, MN
Paul
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575 posts in 480 days
posted 170 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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1484 posts in 268 days
posted 170 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
-- if you aint the lead dog the scenery never changes
Russel
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1022 posts in 327 days
posted 170 days ago
Absolutely ingenious. Your creativity and resourcefulness are downright inspirational.
-- If at first you don't succeed, try again. Then quit. No use being a darn fool about it.
Al Navas
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183 posts in 263 days
posted 170 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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1809 posts in 474 days
posted 170 days ago
Just shaking my head….amazing….
-- Bob, Carver Massachusetts, Sawdust Maker http://www.capecodbaychallenge.org
CedarFreakCarl
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280 posts in 442 days
posted 170 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 Cain
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4290 posts in 687 days
posted 169 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
-- Dick Cain, Hibbing, MN. http://www.woodcarvingillustrated.com/gallery/member.php?uid=3627&protype=1
mrtrim
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1484 posts in 268 days
posted 169 days ago
-- if you aint the lead dog the scenery never changes
miles125
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837 posts in 394 days
posted 169 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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1484 posts in 268 days
posted 169 days ago
i guess a meeting of the l. j. roundtable
-- if you aint the lead dog the scenery never changes
cheller
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223 posts in 497 days
posted 168 days ago
Great solution, and very nice hinges.
-- Chelle http://artsgranddaughter.blogspot.com