Nate Nagel wrote:
On 07/09/2010 07:39 PM, aemeijers wrote:
dpb wrote:
N8N wrote:
...

shim stock or shingles could be made to work but would require a lot
of planing/sanding, is there any wood product that you can think of
that is flat and 3/16" or more thick (but obviously not so thick that
it would require excessive planing/sanding when done) ...
...

A small piece of pine w/ decent grain and a (sharp) block plane will
make quick work of it.

--

And we have a winner! Don't over-think this, it isn't that hard. Square
up the hinge mortises with a sharp chisel, and cut a square-cornered
tight-fitting plug slightly too thick, and glue it in place. Maybe pin
it with a brad till glue dries, if you don't have a convenient way to
stack weights on it. I think I used Gorilla Glue last time, because it
was handy, but yellow carpenter glue is the traditional material. Resist
the urge to touch it until the glue tries, and then plane and sand. Once
painted, you won't even be able to find it.


right, but the reason I was asking was that I don't have a table saw, so
no way to make thin pieces of pine from scrap 2x4 or what have you. I
know, I really *should* get one, but...

nate

For a tiny job like this, one of the 5-buck plastic miter boxes and saws
will work fine. Just buy a stick of trim at the borg- labeled 'screen
mold', probably- and cut the ends square. They will have something
pretty close. You can whittle the width pretty close with a fresh blade
in a utility knife. For that matter, for pine that thin, you could make
all the cuts with a utility knife, if you are patient and have a good
square. You only need to end up with one flat face, and 3 flat edges-
the rest will be handled by the planing and sanding.

These are the kind of jobs Harbor Freight tools are good for. Something
you'll probably only do once every five years.

--
aem sends...