In order to make the hinge for the smokebox door I first created an elongated hinge and jig. Not perfect, but gave me a good alignment of each side. This alignment of each side of the hinge is important. Fundamentally an aligned hinge works better. This being the smokebox for the 1/20th scale Burrell traction engine everything is small.
The brass etched door panel has been silver soldered to the mild steel door. This door has then been bolted to a stainless steel plate.
The brass tube is for both halves of the hinge. Hopefully you can just see the head of one of the bolts that forms the other side of the hinge. The two bolts will have a small piece of brass tube fixed to the heads and these will bolt to the smokebox frame.
In this photo the hinge points have been extended in length, thus reducing the likelihood of brazing them all together. At the same time allowing them to all be aligned.
At the back of the jig you can see the bracket locking the door in place. Also, you can see the 2 bolts that form the other side of the hinge poking through.
The two brass bolts are 8BA and I filed the domed heads so that the brass tube sits snugly in the head of the bolt.
The bolt through the centre of the door is 10BA and is just there to lock the door in place, hence the stainless steel bracket at the back.
The elongated hinge and jig have allowed me to silver solder the tube and align everything.
At this point I’m a tad worried about the silver solder that has run onto the surface of the brass etching.
Offering the door up to the smokebox shows the extent of the elongated hinge.
The long brass tube now needs to be cut at a number of points, thus creating the hinge. The important thing is that this long tube means it is all aligned. I know, I keep repeating this, but hopefully this is obvious at the next stage.
Aligning and Cutting to Length
The steel piano wire used in the centre of the hinge is used to mark the smokebox and hence locate the holes for the bolts that form the other side of the hinge.