I use 60% of the door width as the overall length of the hinge.(pretty close to 2/3) For man doors, I use either 1/4 x2 or 3/8 x 2. For barn or garage doors, I use 3/8 x2. I usualy punch square holes for carraige bolts, unless I am also making the bolts. ( I make fake carraige bolts, no square part. Its just not worth it.) If I have to make bolts, I always use 304 s.s. I head them in my 75# mechanical power hammer that I built. I make mostly colonial style hinges, because of my location. Lately, I have been having my hinges color-galvanized(black naturaly). This is a great deal for me and my clients. Last week, 38 hinges, 30" long, hot dipped, epoxy primer, polyurathane top coat, for $214. About $5 a hinge. I can't paint them for that, and I don't like painting anyway. For colonial style restoration jobs, I believe the length of the hinge should be more like 90-95% of door width, as the oldtimers were far too practical, to not use the iron to hold the door together as well as hold it up. A note on installing strap hinges: mount the pintal first. With the strap on the pintal, hold the strap a few degrees above level. mark the pintal holes, bolt the pintal to the door frame. Put he strap back on the pintal. Push the strap against the door, pull the end of the strap down till it is level. mark,drill, bolt etc. You will like how the door stands and swings if you do this.  |