Tool Box Lid cut and hinge

The Lid Cut separates the tool box into two parts.  The top being 1 1/8"

 

Before cutting the lid off be sure to inspect the tool box for any glue bumps or uneven joinery.

A block plane quickly levels uneven surfaces.

 It is best done on the table saw. Note the splitter is installed for safety

 

Preferably, the box should be lying on the long side for the last cut. So we'll start on the short side

 wedges are taped in the kerf to keep the operator from collapsing the lid and creating an uneven cut.

 

Watch Daniel complete his last cut. The kerf splits in two to reveal two perfectly even surfaces.

 Next a hacksaw divides an 18" portion of piano hinge

 The hinge will be mortised halfway into the box and lid

This means the mortise will be half the width of the closed hinge (actually a little less)

 

the ball or knuckle will stick out the back of the toolbox. Folding it over makes for an easy lay out.

 Yes that's half the gap.  about 1/16"

 a jig will be made for this trim router.  This reqires some MDF or plywood. Then tracing the holes from the original router base and reproducing them. Make sure those screws fit in nice and flush.

 Now attach the new MDF base to the router

After finding the edge of the bit with a sliding "T" square, a base line is drawn on the MDF

Then a second parallel line is drawn to represent the width of our hinge (5/8" not including the ball)

Now to test it, two test pieces are needed.

The bit is round, but the hinge is square. Get as close as you can to the end layout line. Then finish with a chisel (or knife on pine)

 Do it again.

 The fence sets a a base line at the back of the mortise that the hinge butts up to.
This guides the hinge in place during installation so test and test away until you get it right.

A centre finder can be helpful to pre-drill the perfectly. If your screw is off centre it will pull the hinge out of place causing alignment problems

 Drive these screws in by hand. over tightening and stripping the pine is easy to do.
Take your time

"Use the force"

 

only 2 screws per side is required for this test.

 examine the gap left when the hinge is closed

This gap is too big

 it should close all the way without resistance yet have almost no gap.

 

Be aware that the screws pert-rude and sometimes prevent the hinge from closing. 

Space them out so they don't close one on top of the other by skipping every second hole.  

This may be unavoidable on the ends though.

Be sure the hinge is tight up against the edge of the rebate.

  The moment of truth!

once the hinge is installed, go ahead and sand the outside of the box.

Cabinetmakers will sand pine with 120 to take out processing marks from machines.

 Then 150 final sanding. Higher grits depend on finishing procedure.

 it is however possible to do this free hand.

Watch *another Daniel do this with his router by simply laying out his mortise and free routing.