Diagrams for Forging a Butt Hinge

Step One:

Heat a piece of flat 1/8-inch thick by 3-inch wide bar stock to bright orange as seen in low light. Use a cutting hardy or hot chisel to cut the bar as in the diagram.

Step Two:

Reheat bar to bright orange. Place bar on anvil as shown in Figure A and make the first bend by striking the bar at a 30-degree angle.

Figure A

The bar will look like Figure B once it is bent. The drawing on the right is a front view of the left hinge piece. The right hinge piece will fit into the blue space in the center.

Figure B

Step Three:

Bend hinge ends around a forming pin as shown in Figure C. This is the first bend.

Figure C

This is the second bend:

Figure D

Step Four:

Adjust the pin as in Figure E1 and E2 for a snug fit.

Figure E-1

Step Five:

Peen one or both ends of the pin as in Figure F to make an open or closed hinge:

Figure E-2

Strike the pin at a 30-degree angle as in Figure F.

Figure F

When finished, your hinge will look like Figure G:

Figure G