Silvan wrote:
Ray Dunn wrote:


looks great, I struggle with attaching the hinges. Usually after
attaching the hinges and closing the box, the top is a little to the left
or right or not quite flush to the front. It's a pain to do all this work
and not have the top line up.


What methods are being used to make the cuts for the hinges and how do you
hold the base and top to ensure precise alignment.


Well, *I* feel your pain. You've gotten a lot of "cut this, then clamp the
two together and mark the other part, then cut that" stuff, but it doesn't
answer the fundamental question. The problem is that once you've got
hinges on the bottom part, the other halves of the leaves have to be marked
on the lid, and if you put the lid on the box, you can't get inside it to
mark where the hinges go. Catch 22. So you're left with a completely
unsatisfactory process of fiddling and jiggling and having everything come
out a little crooked in spite of all that. Does this sound familiar?

I have about concluded the the only thing to do here is make the lid a
little oversized to the front and sides. Mark the hinge locations on both
pieces, chisel out half the barrel height from each piece, screw the hinges
on, then plane the top until it matches the bottom perfectly. I've tried
all kinds of ways of clamping the lid perpendicular to the box so I could
mark the hinge locations, and it never comes out quite right. I think
doing it all unfinished and planing away the little bit of extra is about
the only way to ever get there.

Here's my 2 bob's worth
Mark and set the hinges in on either the top or base.
Cut down some of the screws which you will be using to fix the hinges so
that when they are place through the hinge you only have a mm or so
showing. Sharpen the ends with a small file or if you've more then ten
fingers on a grinder.
Place the lid (or base) in position. It should now be sitting on the
sharpened ends of the screws. Give it a sharp tap and presto, you have
centre marks for the screws. Screw a spare hinge in place, mark around
it and let it in.
Has been working for me for years.
Hope I explained this satisfactorily. I find doing a job and telling
someone how to do it two very different things
all the best
John