How to Cut Door Hinges With a Dremel

Introduction

How to Cut Door Hinges With a Dremel

A hinge is a mechanism on the edge of a door used to swivel and allow it to open. A hinge allows movement at two points. When you look at old houses, you will notice that the hinges have been attached through holes drilled in the muntin boards and also directly into the frame of the door itself. Today most wood doors are installed with “mortise” hinges with large horizontal holes cut out into the frame for each hinge. This was done mostly due to new materials being stronger than old ones and because people care less about their house’s appearance nowadays. Today I will be discussing how to cut door hinges with a Dremel. So let us get started.

What is A Dremel?

Dremels are rotary tools used to polish, cut, carve or etch almost anything. They transform an ordinary worker into a creative artist by giving him the freedom to cut into any surface. The versatility of Dremel makes it one of the most popular and widely used power tools available in the market today. 

Step-wise Guide on How to Cut Door Hinges With a Dremel:

A door hinge is one of those things that we see every day but never notice how it’s made. However, on closer inspection of a hinge, you will find out that there are two metallic plates on either side (usually attached with screws) holding the actual hinges in place. These plates are what we call door hinges.

Things That You Will Need:

A sharp Dremel tool. A Dremel makes the job so much easier, especially if you have to make multiple cuts. If not, then a good old hacksaw will also work just fine.   A vice-like grip on either side of the hinge plates to apply enough pressure to cut through metal. Safety goggles and gloves round off the basic list. Wearing both your safety goggles and gloves is important because they help protect your eyes (from razor-sharp metal shards flying around) and your hands (from getting cut by the metal hinges).

Step 1: Prepare Your Dremel Tool For Cutting.

Wearing your safety glasses and gloves, insert the tip of the Dremel tool in between the plates at one end of the hinge. The plate should be placed on a flat surface while you do this to make sure that it does not move around as you work with it later.

Step 2: Cut Through Both Surfaces of Each Door Hinge With Your Dremel Tool

Use your Dremel tool’s toughest grinding stone and push it across both metal plates at once to start cutting them out. Keep pushing forward until they have been fully cut diagonally.

Cut Door Hinges Surface

Step 3: Repeat the Same Process at the Other Plate of the Door Hinge

Once your first two cuts are finished, move on to repeat the same process as before for the second plate of your door hinge. Cut through both plates diagonally, so you don’t end up with a U-shaped hole in your metal cutouts.

Step 4: Separate Both Parts of Each Door Hinge by Removing All Screws or Nails, Holding Them Together

This is perhaps one of the most tedious parts of this project and will require patience and perseverance. First, with a screwdriver or drill at hand, take out every single nail that holds either piece of the door hinges together using some good old elbow grease. It may be helpful to have someone else hold the hinge still while you remove the nails.

Step 5: Complete Your Door Hinges Using Some Hollow Tube.

Your new door hinges are now complete, allowing you to cut through at an angle when making further cuts into a wooded surface like a table or shelf. You can use the existing holes on either metal plate for screwing these newly completed hinges onto any wooden frame.   For standard-sized doors and cabinets, 5/8″ to 1-1/2″ in inner diameter hollow tube of steel should suffice as a suitable material for your DIY door hinges. Just remember that while cutting open this hollow tubing, be sure not to make it too wide because it will lose its rigidity over time with regular use. Once done with one end of the tube, connect the two ends to complete your DIY door hinges. You can then attach it to any wood frame or table using some commercially available adhesive.

Step 6: Attach the Completed Door Hinge Onto a Wooden Framework and Use It as Required.

Depending on what you want to attach this new DIY door hinge onto will determine whether your hinges are needed to be longer or shorter than usual. When attaching these new door hinges on your own homemade doors, keep in mind that different types of wood require different lengths of time when applying coats of paint and varnish.

Also, especially for freshly made hardwood doors, always apply appropriate layers of protection over its skin before trying out any mechanical attachment like this one, so you don’t end up damaging the wooden surface. That’s about it for this project, and now you know how to cut door hinges with a Dremel tool.

Attaching Door Hinges

Safety Tips While Performing How to Cut Door Hinges With a Dremel

Always wear the necessary safety gear. Don’t take any chances with your eyes, face, and hands while using power tools or working with anything that could potentially Be when you. When cutting door hinges with a Dremel tool, always use safety goggles to protect your eyes from possible splinters and metal shards.

You should also be wearing gloves to protect your hands from cuts caused by sharp edges of metal fragments. Lastly, wear earplugs if you’re going to be doing this job in a noisy environment like an apartment building hallway during the morning commute or at night when people are trying to sleep. You don’t want other people hearing what’s going on in your room as you’re cutting dangerous metal objects close to where they may unknowingly be passing through.

Please familiarize yourself with your power tools and door hinges before trying to cut them open.

Always keep track of the direction in which you areFor example, doorting. Door hinges usually have markings on one side to indicate which way they should swing and open. You can also find these instructions on the packaging if you buy a new item instead of using something old from around the house.  

Can I Use a Router to Cut Door Hinges

If you are planning to make many cuts with the router, then it may be better to buy an actual door hinge cutting template. They are typically made out of steel and can be purchased at your local hardware store or online. You would set the template on the wood using some wax as a lubricant (so that it doesn’t stick), clamp it down tight, set up your router, and make several quick passes until cut through all layers. Door hinges are not something that I use a router for except in rare circumstances, so I save time and have avoided buying one. That said, if you are going to do any serious woodworking work with your routing setup whatsoever, it’d definitely be worth looking into getting this cutting template.

Use A Router to Cut Door Hinge

Router vs. Dremel Tool For Cutting Door HInges

A router is a powerful tool but can be dangerous when misused. For example, I recently used my router to cut the hinges on an antique cabinet, not knowing what I was doing.  The result:  I destroyed the hinge!

If you’ve ever tried to cut door hinges with a Dremel tool, you have probably noticed that it is not easy.  It is a little more difficult than simply using your drill or sliding your belt sander in there and rough cutting them off, as most people do.

The problem occurs because the material you are working with (metal) tends to heat up and expand, which will cause it to warp, change shape and open under pressure while using any power tools.  This can lead to possible accidents and injury.

Do not use power tools for cutting door hinges with a Dremel!  It’s dangerous and can lead to injury!

The First thing you need to know is the difference between a pre-made hinge versus a custom-made hinge. Pre-made or off-the-shelf hinges (typically sold in hardware stores like Lowe’s, Home Depot, or Ace) are usually designed to fit doors 36 inches wide or less. Custom-built hinges are designed to fit your specific door width no matter how narrow they are, so if your door is only 26 inches wide, then you’ll need custom cut blades: buy a special miter box cutter.   However, even with custom-made hinges, you can still cut them down.

The general rule of thumb is to make your cuts at a 45-degree angle with the saw blade going into the hinge from top to bottom if possible (or whichever way feels more comfortable and natural). 

If there are any posts on the hinge, space your cuts around them so that they fall onto one of those posts instead of in between two posts where it will weaken the hinge: buy a special miter box cutter.

This is very important!  When you start making your cuts take note of how long or short you have to go for each side.  Ensure both sides are the same length when you finish cutting so that they are parallel, or your door will not close properly.  If you will be cutting a lot of door hinges, then the best tool for the job is a miter box like this one: buy a special miter box cutter. It gives your saw blade a greater range of motion with more stability which equals less injury while doing the job!

Conclusion

I hope this article has provided you with all the information on how to cut door hinges with a Dremel. Thank you and have a nice day!

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