INCRA HingeCrafter - Manual (Page 7)

Before removing the hinges from each end of the blank, make the
safety push stick described in the full-scale plan included with this
manual. Use
3 / 4 ” plywood and cut out the push stick with a band saw
or scroll saw. Sand the push stick to remove any sharp edges around
the handle.
Set the fence to blade distance at your table saw equal to the hinge
barrel diameter plus 1”. (Example: For the
1 / 2 ” barrel diameter set the
fence to 1 1 / 2 ”.) With the rounded end of the blank against the fence
and the hinge leaf dado face up, use the push stick to move the blank
through the cut,
Fig. 22. Repeat for the opposite end.
CAUTION: Never make the above-described cut with the hinge
leaf dados face down.
Before cutting your finished hinge to final width, carefully assemble the
two halves of the hinge blank and install the brass hinge pin. If you
experience any difficulty installing the hinge pin, you can run the drill
bit back through the hinge to clean out any chips that may be blocking
the holes. After installing the brass pin, close the hinge and carefully
remove the hinge pin. This aligns the hinge parts for cutting,
Fig. 23.
CAUTION: Never make final sizing cuts with the brass pivot pin
installed.
The final sizing of your finished hinge must be accomplished by
making the cuts using a crosscut box or miter gauge
carrier as shown in
Figs. 24 and 25. Although these cuts
appear to be crosscuts, they are in fact short grain rip
cuts and require backing support for safe cutting. Each
of the methods of cutting shown provides necessary
backing support for the hinge blank on both sides of the
cut. Dimensioned plans for the miter gauge carrier can
be found on page 8. Hold the squared end of the hinge
assembly firmly against your crosscut box or miter gauge
carrier back fence
as you make the
cut. Determine
the final cut width
depending on the
requirements for
your application. In
general, the smallest
hinge should have
five knuckles for
maximum strength
(three on one side
and two on the
other).
INCRA HingeCrafter 7
FIG. 21
Drill extra long hinges
FIG. 22
Crosscut ends
FIG. 24
Crosscut box
FIG. 25
Miter gauge carrier
NOTE: Owner’s manual photos
show the blade guard removed
for instructional clarity only. You
should use your blade guard and
other safety equipment whenever
appropriate to protect yourself.
Refer to your equipment manuals
for proper safety instructions.
CROSSCUT ENDS
RIP HINGE TO FINAL WIDTH
For extra long hinges, first drill one end of the hinge blank, then
unclamp, reposition and drill the opposite end of the hinge blank.
Finally, unclamp and reposition with the center of the hinge in the
HingeCrafter and drill through the existing outer holes to reach the
center. For the longest hinges it will be necessary to complete the
holes in the center by drilling from both ends and in a few cases a
third repositioning is required,
Fig. 21.
First: Use
HingeCrafter to
drill outer holes
Second: Reposition blank
to drill interior holes
Use safety
push stick
Set fence to blade distance at
hinge barrel diameter plus 1”
Make cut
with hinge
leaf dado
FACE UP
Install, then remove brass pin
to align hinge parts for cutting
FIG. 23
Align hinge parts