just installed some beautiful Horton Brass butt hinges on a small box for a friend.The hinges are top quality as usual, but I planed the top a little too thin and the screws came through! . I figure my options are to make a new thicker top, trim the screws, or try to buy shorter screws. If I back off the screws, the hinges are loose. I will have to fill the pin holes in the top if I don’t make a new one. Any suggestions ? [email protected]
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Replies
Remove the screws, nip of the ends with side cutters or file the end down.
To hide the holes I would rout a shallow recess around the top edge of the box and fill with a decorative timber to 'frame' the top.
You'll probably spend more time trying to figure out a get around for your mistake than just cutting your losses and remaking the part. You already know how. Stay with your original design and use a shorter screw if a shorter screw will work. Make the new top slightly thicker if a shorter screw won't work. Two choices!
You could always embrace the screws as part of the design - the trick is getting them all to protrude the same distance and filing and sanding so they look the same - I've done this once deliberately when I felt I needed the full thickness to hold a larger door made from thinner material. It looked ok. Not flash though, but ok.
Remaking the top would be my first choice. If you try to save the current top, the filled holes will mock you for all eternity.
You can always shorten a screw, by cutting or grinding. For centuries, hand filed screws were very blunt.
This is a learning experience. Remake the top to a thicker dimension, or make it the same and shorten the screws (or both). If the screw pilot holes are the right diameter you don't need a point on the screw anyway.
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