Making Wooden Hinges

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Technical drawing showing top and right views of a wooden hinge with hinge pin holes and separation lines for two halves.
Three wooden hinges showing interlocking knuckles and a pin hole for assembly

You can use metal hinges on the box, but I prefer to make my own out of the woods I’m using. You can use scrap wood to make them, and it’s just a few more cuts with the scroll saw. But it’s worth it to have perfectly matching hinges for your box!

Hands cutting a wooden hinge pattern on a block using a scroll saw in a workshop

Rough out the hinges. Start by making two photocopies of the right view hinge pattern. Attach the patterns to the hinge blank using the glue stick. Cut out this profile on the scroll saw. Attach the other pattern to the opposite side (so you know where to drill, see Step 2).

Hand holding wooden hinge block while screwdriver drives screw into pre-drilled hole

Step 2: Drill an 1/8"-diameter hole half way through the hinge blank where marked on the pattern. The dimple from the center punch will help to line the drill bit up properly. Support the hinge with a block of wood. Then turn the blank over and drill another hole where the diagonals connect. Drill deep enough to meet the hole drilled in the other side. Follow the same procedure to drill the hinge-pin hole on the opposite end.

Hands using a coping saw to cut a small wooden hinge piece marked with pencil lines

Step 3: Cut out the hinge barrels. Attach the top view pattern to the hinges and cut along the solid lines. Do not separate the hinge halves until Step6.

Hands assembling a wooden hinge with two cylindrical knuckles on a workbench.

Step 4: Round over Side A of the hinge using a detail sander or belt sander. Then round off one corner of Side B—leave the other corner square. The square corner will act as a natural stop and prevent the hinge from opening more than 100° to 110°.

Hand holding wooden hinge while screwdriver tightens screw in workshop setting

Step 5: Mark one of the two hinge barrels on Side A with an “x.” Use a 9/64"-diameter bit to enlarge the hinge-pin hole on that side a little bit. Do not enlarge hinge-pin hole in the other hinge barrel on Side A. Then reverse the hinge and use the 9/64"-diameter drill bit to enlarge the hinge-pin hole in Side B.

Hands marking precise hinge pin placement on wood using a fine saw blade and paper template

Step 6: Cut the hinge in half following the lines on the pattern.

Hands assembling a small wooden hinge with a dowel pin in a workshop setting

Step 7: Dry assemble the hinges, following the hinge assembly diagram, using a nail that fits loosely through the holes. You want to make sure that the hinge opens the proper amount and doesn’t catch or bind at any point.

Hands bending a small wooden hinge joint to test its flexibility in a workshop setting

Step 8: Mark any places where the hinges bind. Sand those areas until the hinge opens freely.

Hands cutting a small wooden hinge piece with a scroll saw blade in a workshop setting.

Step 9: Assemble the hinges using an 1/8"-diameter dowel. Glue the dowel in place using wood glue. Trim off any overhanging dowel with the scroll saw and sand the area smooth.

Woodworker wearing safety glasses in workshop, preparing to make wooden hinges

About the Author

Gary has been scrolling since 1992 and has been making jewelry boxes on the band saw and table saw since 1986. Designing and making jewelry boxes on his DeWalt 788 saw are his primary interests. This is Gary’s second article in Scroll Saw Workshop. His first article was “Octagonal Jewelry Boxes”, featured in Summer 2004 (Issue #15). Gary’s other interests are golf, gardening, and attending craft shows.

This project is courtesy of Scroll Saw Woodworking & Crafts Magazine.

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