Blacksmithing Tips: Making Hinges

Hinge Types

• Various types of hinges are made by blacksmiths depending on their intended uses. A basic hinge is the strap hinge often found on old barn doors. This simple hinge is composed of two parts consisting of a long, flat metal strap piece with a circular opening and a shorter pintle piece, which is a pin or bolt that fits into the circular opening. The strap usually extends about one foot across the front of the door with the pintle piece bolted into the frame or post at the side of the door. Butterfly, or dovetail, hinges are smaller hinges often used for cabinet doors. These are formed from two mirror-image pieces that fit together at the center along the hinge barrel. When fully opened, the hinge looks similar to a butterfly.

Materials

• Hinges can be forged from a variety of materials. Consider the cost and the purpose of your hinge when selecting the material to be used. Steel is the most common metal used in making hinges and is suitable for most projects. Stainless steel and brass are also commonly used. Bronze is a more expensive metal that can also be used in making hinges.

Pattern

• Create a paper pattern for your hinge. You can use an existing hinge as a template. Your pattern should show the outside shape of the hinge, the holes for attaching the hinge to the door and the marks for the cuts needed for the hinge barrels. The two pieces of the hinge will fit together at the center, so the hinge barrels should have interlocking cuts similar to the teeth found on a gear. You can glue your paper pattern directly onto the metal using rubber cement. If you will be making multiple copies of the same hinge, make a photocopy of your pattern and glue that to the metal.

Die

• If you are making more than one copy of the same hinge, you want to make a die for making your barrels. A die is a special mold used for shaping molten metal. The barrel encloses the small pin that fits into the center of the hinge. The die should be made from steel. Drill a hole in the steel that is slightly larger than the thickness of the pin and twice the stock thickness. Use a hacksaw to make an access cut down to the hole from the top of the metal sheet. File the cuts and polish the die before using.

Files

• The file you use in making your hinge should have one smooth, or safe, side. This smooth side is placed against the part of the hinge that is not to have material removed, such as along the barrel of the hinge. Examples of file types you can use in making hinges include a square bastard file that is 6 to 8 inches long and a fine, flat file that is 6 inches long.