Bob Savage wrote:Looks excellent Michael.
Question: How did you attach the chain? I can't tell if you have just a screw holding it to the lid/box. It looks like there might be something else there too?
One other question: I've not used these type of hinges before. You guys are calling them 3/4" hinges but Home Depot and True Value guys are telling me I'm actually looking for a 1 1/2" hinge, which is 3/4" to the center but the hinges look too big for the hinge pocket in the box.
And finally, does the hinge just screw on top of the underside of the lid, no relief required?
I've got my parts cut and am hoping to finish this thing for Sunday!
By the way, thank you very much for putting this project up.
Excellent questions. I used #6 Brass Flathead Phillips Wood Screws and #6 Brass Finishing Washers to attach the chain. Finishing wahsers are sort of a "dished" raised washer - kind of looks like a bagel split in half. All those items were purchased at Lowes, but any well-stocked hardware store should have them.
The hinges measure 3/4" wide when opened. The back panel of the box layout has a vector that will automatically cut a dado for an 8" x 3/4" piano-style hinge. However, you may need to use a different hinge(s) if you cannot readily locate a piano hinge that size. I believe any hardware store or something like a Michael's Arts & Crafts will have a variety of 3/4" hinges you could use. Be sure to modify (or delete) the hinge/dado vector in the back panel layout to suit your hinge choice. You can always chisel the hinge dados by hand (that's what I usually do except when I can get away with the machine doing it for me!).
I did not design a recess/dado in the top - that was primarily to keep things simple - i.e., no two-sided indexing required. The hinge is attached directly to the flat underside of the lid.
The following tip may be old news to you and others... to help get the hinges lined up properly, I first drill pilot holes and attach the hinge into the dado, then fold it over (to the closed position). I often put folded scraps of paper between the hinge halves to temporarily keep the hinge flush with the the top edge of the box. Then I use a few dabs of hot glue on the exposed surface of the hinge and place the lid on top, pressing down a few seconds. I carefully open the lid and mark the screw hole locations with a pencil and then drill pilot holes onto the underside of the lid. After verifying fit, I remove the screws and hinge, then apply my finish. Don't use too much hot glue, or it will be a bear to release the hinge from the lid before finishing!