Just for Fun... #10: Some Assembly Required...

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Blog entry by littlecope posted 01-05-2010 09:36 PM 1685 reads 0 times favorited 11 comments Add to Favorites Watch
« Part 9: Back at it... Part 10 of Just for Fun... series Part 11: Wrapping it up... »

After making the hinges and knob in Episode #9, it was time to return to the box again. I had taken the time to sand the sides as I went, so all that was left to sand were the panels. After that was done, I was left with a difficult choice. Both panels looked good as the top, and turned either way, forwards or backwards! I finally made the choice (probably the wrong one) and it was assembly time.
Clamped one side, with the handle next to the desired corner…First one clamp...
Then the Other…then the other.
This whole makes a surprisingly well-balanced package for Drilling the holes.A Well-balanced package
Set the depths of the holes..Setting Drill stop depth
Cut some pins out of dowel and sand the edgesSanding pins after cutting
One last thing before drilling, scoring a pilot, to start the drill in the correct spotScoring for Drilling
Drilling the hole: Drilling the hole
When I tap in the pins, I form a sort of “sleeve” with my fingers to avoid snapping them in half while strikingForming a sort of "sleeve" with my fingers
Then I simply trim off the excess pinsCutting off excess pins
I’m going to round over all the edges, but I start with a chamfer, marking it with some scrap 1/8” Lexan that’s kicking aroundMarking Chamfer
Then roughing those with the Scroll Saw tilted to 45°Table tilted for cutting chamfers
I’ll spare you the filing and sandingFile and Sanding time
But when I’m satisfied, it’s time to part the top from the bottom. I try not to make more of this than it is. It seems when I’m most careful here, I have the least straight cut…This time I tried not cutting through entirely and then slicing it free with a Utility Knife. It seemed like more work having to clean it up afterward, but it worked tooA Quick Parting
After cleaning those edges a little, I clamped it up in my hinge attaching clampThe Clamp Set-up for Gluing the Hinges
Applied GlueApplying Glue
And set the hinge using a spacer strip. (Note: I also put pencil marks over the pivot pins, so I just line these up to the “break” in the box.)Attaching First Hinge (using spacer strip)
This all took about four hours this morning, what with all the Picture taking…Enough for Today
I almost forgot, before I devoted the bench top to clamping and gluing, I took a minute to add a second coat of red paint to the knob. A couple quick squirts, wearing a freezer bag over my hand (all out of gloves) and Presto!A Final Detail
Now I’ll just wait until the glue dries or I get my next chance to get back to the fun, whichever comes first… :)

-- Mike in Concord, NH---Unpleasant tasks are simply worthy challenges to improve skills.

11 comments so far

View ellen35's profile


2739 posts in 3671 days

#1 posted 01-05-2010 10:16 PM

Cool… very cool, Mike.
Those hinges is something else!
Great box!

-- "Don't let the perfect be the enemy of the good." Voltaire

View Kristoffer's profile


675 posts in 3454 days

#2 posted 01-05-2010 10:38 PM

You should try giving those hinges a dorsal fin. Every since you started flaring out the ends, I’ve kind of thought that they look like a large mouth bass. It might make a nice addition to a lure box or something. Just a thought. Nice job, when can we expect #11?

-- Cheers and God Bless

View Dick, & Barb Cain's profile

Dick, & Barb Cain

8693 posts in 4538 days

#3 posted 01-05-2010 11:37 PM

Very nice Mike!

Your hinges keep getting better.

-- -** You are never to old to set another goal or to dream a new dream ****************** Dick, & Barb Cain, Hibbing, MN.

View degoose's profile


7245 posts in 3593 days

#4 posted 01-05-2010 11:56 PM

This is fantastic, just gets better… cant wait to see the finished box..Loooove the hinges…

-- Don't drink and use power tools @

View HallTree's profile


5665 posts in 4006 days

#5 posted 01-06-2010 12:47 AM

I like the detail photo’s of the progress. Nice job. Looking forward to see the finished project.

-- "Hold on to instruction, do not let it go; guard it well, for it is your life" Solomon

View patron's profile


13641 posts in 3579 days

#6 posted 01-06-2010 12:53 AM

sweet sequence !

well done , mike .
i heard that
jao fing ,
hwig dwo ,
and lui lhan ,

are looking into this idea .
their problem , is that they can’t compete ,

all of their efforts look too mass produced !

’ Yankee ingenuity ‘
doesn’t grow on trees ,
over there !

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View studie's profile


618 posts in 3385 days

#7 posted 01-06-2010 06:08 AM

Great to see you back in the shop, didn’t take long either. Thanks for taking the time & effort to show your procedures. I need to learn how. I love to take pictures but to post them in a series like this I think I need to reduce the file size. I have Photobucket but have to put my pic’s in it then work from there. Nice box again Mike! The last box I made I cut just thru on the long sides then used shims to hold the saw kerf with clamps & tape. Cutting then the sides free and no saw bind.

-- $tudie

View scrappy's profile


3507 posts in 3669 days

#8 posted 01-06-2010 07:07 AM

Your hinges are allways so stylish. Just love them.


-- Scrap Wood's the best...the projects are smaller, and so is the mess!

View a1Jim's profile


117417 posts in 3816 days

#9 posted 01-06-2010 07:18 AM

good details

-- wood crafting & woodworking classes

View nmkidd's profile


758 posts in 3411 days

#10 posted 01-06-2010 05:09 PM

The hinges are definitely unique….....great pix and tutorial…....nice box… usual a super job Mike.
Can’t wait to see the the finished product.

-- Doug, New Mexico.......the only stupid question is one that is never asked!........don't fix it, if it ain't broke!

View lumberdustjohn's profile


1263 posts in 3405 days

#11 posted 01-06-2010 06:07 PM

Nice details. Fantastic hinges.

-- Safety first because someone needs you.

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