A lot of the items I intend to make here at Cryptic Woodworks will probably be a form of box. Boxes usually have lids, and lids often need hinges. If you start making products you will probably look at hinge hardware and gasp a bit at the prices. I am wrestling with this problem, I don't want to continue to up the price of the boxes to recoup the hardware cost.
I noticed while perusing the internets that wood hinges are a possibility. "Wood hinges?" I said, I must try this.
I am attempting the scroll saw method. I made a set of 10 hinges in which I let the saw blade separate the barrels. But this produced a sloppy fit, regardless of the fineness of the blade. Then I went and drew a template in Sketchup which I can print out and wrap around a piece of wood. Now the two halves a separate, so if I stay just inside of my lines (or split the lines, as in for a dovetail) I get a good fit. The trick is to very accurately drill the hinge pin holes, which the paper template helps out with.
I made 4 more hinges and I like the fit much better. I actually have to loosen them slightly.
I think I'll like this. Now to put them on the latest set of boxes.