I make a box, cut the top off then always run into the same problem -
hinges. I can _never_ get them set properly the first time. I mainly use
Brusso hinges and I've seen a technique whereby the lid is placed next to
the box with a spacer and spring clamps and you proceed from there. But I
still seem to have problems with the lid being slightly off-center at
times (and I use one of those center-finding punches to create the initial
drilling indentation). So I'm looking for a better technique. Anyone
have a fool-proof method of getting hinges aligned perfectly the first
Mike, I use Brusso hinges too, and found that the center-finding punches
don't work worth a damn. I mount the hinge flush with the inside surface to
everything's matched up, and do the lid first, then the box, rather than
clamping the two together. I use a sharpened icepick to mark dead center in
each hole, then an awl to deepen that mark, then a 1/16" bit to make a pilot
hole. It's quicker than it sounds.
Brusso also sells templates for mounting their hinges
(http://www.brusso.com/templates.html ) but I'm too cheap and hardheaded to
Another tip: If you've filled and re-drilled to the point where a hole is
oversize for the screw, a little piece of broom straw works nicely to make
the screw snug again.
On Wed Feb 25, Ratchet disturbed my nap when he said:
Great - thanks. When you say "dead center" it sounds like you do more
than eyeball it but I'm guessing that's just what you do?
Maybe the centering tool (or my blind reliance on it) has been my problem
all along and not so much my hinging process. I've noticed more often
than not that my problem is that the lid is slightly cock-eyed but
otherwise mostly flush with the box sides. Obviously that indicates screw
holes/centering tool/drilling. With a door or something it wouldn't be
noticeable - for small boxes this tool is probably just too sloppy...
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