ORIGINAL: AA5BY

If a gas size plane last very long, CA hinges are not adequate. I also use DuBro hinges but have changed my installation procedure from the difficult task in the past. I now use a multi tool to cut the hinge slots. I don't know about other brands, but the Harbor Freight cutting head is a perfect thickness for the DuBro hinges. Where the old method took a couple of hours of significant effort inserting a forked cutter into the knife slice and then digging out center with unpredictable slot thickness, the multi tool is simple and fast taking about fifteen minutes to cut all slots perfectly.

Cutting the slots does require some hardwood strips as a resting guide for the cutting head. These are clamped/screwed to the bench and the part needing the slot brought to and against the guide by shimming the part so that the guide will provide a center cut. The cutter head then rest on the hardwood strip and pushed into make the slot cut.... all very easily done and a perfect thickness cut for the hinges.

After slotting, I use a rotary tool (dremel) with a cone cutter to provide the recess for the hinge line. The tip of the cone cutter keeps the tool in the slot and easily makes the necessary relief cut for the hinge pins.

Gluing... I still use 30 min epoxy but have changed how it is inserted into the slot. I used to insert by coating a #11 blade and working into the slot. I now make a paddle from plastic slightly thinner than the hinges that fits into a knife blade holder with a half dozen holes drilled into the paddle to carry glue into the slot. Works great. As always, before inserting a hinge, I fold it together, and dip the hinge line into a drop of 3&1 oil and then blot any excess oil onto a paper towel. The final step is done 5-10 minutes after setting the hinges. Using an eye dropper, one drop of alcohol is applied to the hinge pin and the hinges flexed to insure they are free.

Before gluing the mating slots, be sure there is no oil residue on the hinge. I've never felt a need to apply more oil for the second glue process. I do repeat the process of adding a drop of alcohol after both parts are glued and hinged.