Making a Custom Hinge

 

A commercially available custom hinge can usually be found to suit almost any application. However, sometimes a situation arises when a purpose built custom hinge needs to be made. Such a situation arose when a set of Art Deco security doors had to be installed on the inside of some outward opening courtyard doors. The security doors also needed to be able to open out as well or be left locked while the outer doors remained open.

To enable the inner and outer doors to be totally independent of each other they needed their own hinge but they also needed a common pivot so that they would not foul on each other when opened and closed. This was achieved by making a combination butt/parliament hinge where one flap was longer than the other but they both shared a common pivot flap.

The first step was to find hinges that allowed themselves to be modified into a custom hinge. Eventually a quantity of 90mm butt hinges were found that used 3mm thick steel flaps and had removable finial ended pivot pins. Additional parts to make the extended parliament flap were laser cut in 3mm steel. Once the extension pieces were assembled they could be welded to the required hinge flap. Photos of the installed hinges can be found on the completed installation link.

The pictures below show the steps involved in making the hinges.

Hinge parts

Parts used to make the custom hinge

Disassembled hinges

Two hinges were first disassembled

Making a longer pivot pin

Two pivot pins are joined together to make a longer pin to fit the wider hinge

Joining the two hinges

Two hinges are welded together on one side leaving two independent flaps held in place by the longer pivot pin.

Completed hinge extension pieces

Assembled laser cut hinge extension pieces

Fitting extension piece to one hinge

Fitting an extension piece to one hinge flap

Completed combination hinge

Completed combination hinge

The hinge in two positions showing operation

Hinge operation positions

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