Creative Woodworks & crafts 2004-04, страница 30

Fig. 12. Cutting the center space between the hinges.

reach the end of the hinge pattern line (see Fig. 12). After that, make the two side cuts on the side profile, again stopping at the end of the line.

The front profile is the last cut. Start at the hole and cut around the hinge outline until you get to the line dividing the hinge leaves. Cut that line, stopping just past the outline without exiting the wood (see Fig. 13). Now move back up the dividing line and finish cutting the outline. That completes the cutting of two hinges. They can now be removed from the strip and the waste pieces.

The edge of the barrel (the round part that the hinge pin goes through) is square on the bottom side (see Fig. 14). For the hinge to function properly, this edge needs to be rounded over. This can be done easily by hand with a piece of sandpaper. Because of the way the hinges will be installed, only continued on page 32

edges of the lid and box are then rounded over using a router table and 1/4" roundover bit. This softens those edges and provides a nice definition between the box and lid (see Fig. 8).

Fig. &. After separating the lid from the box, the cut edges are also rounded over.

Stain the box

Natural stain (a light-colored, water-based stain from Cash Coatings) was applied by brush to the inside of the box and lid. The outside was stained by brush with a mixture of 3 parts Natural stain to 1 part Mahogary stain. Three tablespoons of Natural and one tablespoon of Mahogany was enough for two boxes. The sta'n doesn't have to be wiped down after the application; just brush it on and let it dry.

Make the hinges

Both hinges for a single box are cut at the same time using the pattern provided in the pull-out section. Cutting several sets of hinges in one strip gives you more to hold on to while you're cutting. Fold the pattern on the dashed centerline and glue it to the wood you've chosen for your hinges. Use a No. 60 drill bit to drill the hole for the hinge pin. Set the depth stop of the drill press so the bit does not go all the way through the hinge on the top profile of the hinge pattern (see Figs. 9 and 10). The holes only go through

Fig. 10. Setting the depth to be drilled— do not go all the way through the hinge's top profile.

partway because the hinge pins (ordinary straight pins) will be cut off and then tapped into the area not drilled to hold them in the hinge. Carefully drill the hinge pin holes on the center marks on the side profile of the hinges. Drill blade access holes using a 1/16" drill bit on both the front and side profiles (see Fig. 11). As shown in Fig. 11, one hole is for cutting the outline of the hinge on the front profile and three holes are for cutting the center and side lines on the side profile. Threading the blade through these access holes instead of cutting in from the edge holds everything together until the final cut is made on the front profile.

, , The first cut made in the space

j & i__I between the two centerlines

(between the hinges on the side pro-

-1 Q5 t- ; ^F file). The space between them is

^......^/ ....................taken by the kerf when cut with a No.

9 blade. Start at the hole and cut Fig. 9. Hinge top and side profiles. along the space, stopping when you

Fig. 11. Prilling the hinge pin and blade access holes.

Front profile

Fig. 13. Cutting along the line that divides the hinge leaves.

16 • Creative Woodworks 8. Crafts April 2004