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Steel Butt Hinges from Sheet and Rod
A butt hinge is two flat leaves whose curled edges, the knuckles, interlock round a pin. Each leaf's edge is rolled round a rod the size of the pin; slots are cut so the knuckles alternate; the pin goes through and is peened over. Countersunk holes take the screws.
Intermediate
2 hours per pair
Instructions
1
1
Cut the leaves
Cut the leaves
Mark and cut two leaves from 1.5 mm mild steel sheet, 75 by 30 mm plus a curl allowance of about three times the pin's diameter.
Materials for this step:
Mild Steel Sheet0.01 sqmTools needed:
Scriber
Tin Snips
File Set2
2
Roll the knuckles
Roll the knuckles
Clamp a leaf in the vise with a 4 mm rod along its edge and hammer the edge round the rod, a little at a time, until it closes. Do the second leaf the same way.
Tools needed:
Bench Vise
Ball Peen Hammer3
3
Cut alternate knuckles
Cut alternate knuckles
Mark the knuckle into five equal lengths. Saw and file away the 2nd and 4th on one leaf and the 1st, 3rd and 5th on the other, so they mesh.
Tools needed:
HacksawFile Set
Digital Caliper 6-Inch4
4
Drill and countersink
Drill and countersink
Centre-punch three holes in each leaf, drill them for the screws and countersink them.
Tools needed:
Center Punch
Drill Press
Drill Bit Set
Countersink Bit Set5
5
Pin it
Pin it
Mesh the knuckles and push a 4 mm mild steel rod through, cut 1 mm proud at each end. Peen both ends over so the pin cannot slide out. Check it swings freely.
Materials for this step:
Mild Steel Rod0.1 meterTools needed:
HacksawBall Peen HammerBench Vise6
6
Troubleshooting
Troubleshooting
Butt hinge troubleshooting.
Flow
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Materials
2- 0.01 sqmPlaceholder
- 0.1 meterPlaceholder
Tools Required
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