So one of the things that I want to do with my Glowforge is create Magic: The Gathering deck boxes. I was looking for hinge ideas last night and saw this one:
(I apologize if this is something that has been posted before, but I haven’t seen it, and a search didn’t turn it up (though I suppose it could be buried in the multitude of other posts - most of which are about living hinges).)
Note, if you click the image above, you can see the final constructed hinge.
The circle cut out of the inner pieces are left in place and glued to the outer/middle pieces to form the shaft of the hinge. I think its ingenious but I’ve been playing around with it, trying to see if it could be better integrated into the box. This is what I’ve come up with.
This is a very simplified version with no artistic “flare” added yet. The one on the right is the approximation of what the original design is. I thought that part of the circular hinge could be integrated into the box, reducing the amount that sticks out. This design is based on 1/8" ply, (estimating .1125" nominal). So, in the original design 3/8" sticks out the back of the box. In mine that is reduced to 1/4". By integrating into the box I can also remove some of the rounded edges. The red piece doesn’t ever move, so the outer circle is just for looks. For the blue piece, the top quarter of the circle that is in the box lid, moves with the lid, so it can be squared as well.
My other concern is the business of using the circles cut from the blue pieces, glued to the red pieces to form the pin. I’m thinking it may just be easier to get a wooden dowel and use that. It is wholly invisible once constructed, so it doesn’t matter exactly what I use. The only reason that I can think of to use the cut-out piece is so that, if I decide to sell these, I can sell them in sheet form and not have to include any additional pieces, but there is a little sanding that goes into this, as well as some precise gluing, so I’m not sure how viable that is to the end user. Additionally, at 1/8", will these hinges hold up? The box itself is going to be a total of about 4"x3"x3", with a double layer of 1/8" ply forming the shell.