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Hinge Boring for Aluminum Framed Doors

10/19/17       
Pat

Doing a job that calls for aluminum framed doors with glass inserts. The vendor will pre-drill all of the "normal" doors for regular 35mm cup hinges. However, I have one door that is a drop-down that I'm hoping to hinge with flap hinges. The flap hinges I typically use (see link) use 35mm boring that cuts through the edge of the door by a few mm. The door is 35w x 27h and will have 2 stays (hydraulic or mechanical).

The vendor won't pre-drill for this, so I'm wondering if anyone has done this before and can offer any guidance. Is it possible? Not recommended? Alternate hinge suggestions? Another issue with these hinges is the way the screws work. They assume the door is a solid material (wood or similar) so I'm wondering if I could fill the hollow frame around the hinge area with wood blocking to give the screws something to work with.

Thanks,
Pat

10/19/17       #2: Hinge Boring for Aluminum Framed Do ...
Keith Newton

Pat, I believe that the normal hinge boring bit has too low a cutting angle for this. As soon as it starts to break through the inside face, it's probably going to snag as it climbs the face of the blade.

If I were you, I would drill through a wooden template that you clamp onto the aluminum, then use a flush trim /bearing over router bit to make the cut. You ought to ask the supplier to give you some scrap to test on so you can find the best bit.

However, a smaller diameter bit with a wide sharpness angle will work best, so maybe just a straight 1/2 bit using the shaft to rub without the bearing. You can wax the rub area in the template to keep the heat down.

10/19/17       #3: Hinge Boring for Aluminum Framed Do ...
Pat

Thanks, Keith. I had the same thought about drilling with a standard Forstner bit. I'm thinking about using a normal door hinge, which would of course sacrifice the flush appearance that the flap hinge provides.

Still open to other ideas if anyone has any...

Cheers,
Pat

10/19/17       #4: Hinge Boring for Aluminum Framed Do ...
Jarvis

Pat,

I just did a job with those type of doors and I just supplied the vendor with a drawing of what I wanted and the hinges that I was going to use and the did the rest.

10/19/17       #5: Hinge Boring for Aluminum Framed Do ...
Pat

Jarvis,
That's what I've done in the past. The flap hinges are unusual. I sent along pics of the hinge and they said they won't do it. Switching vendors is not an option because the doors use a proprietary patterned glass.

Pat


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10/19/17       #6: Hinge Boring for Aluminum Framed Do ...
Bruce H

I'd probably ditch the flap hinges in this case because of the boring issue. If you screw it up you just bought the door. If you must then the router and jig would be the best option having less chance of failure. Lube the router bit with WD40 (there are other lubes intended for aluminum but this works) a router, lube and sharp bit, it cuts like butter.

10/19/17       #7: Hinge Boring for Aluminum Framed Do ...
Leo G

Depending on how soft or hard the aluminum is, I would just drill it on a drill press. Use a carbide tipped bit, a wood backer for where the hole exits the side and clamp it hard to the fence and table so nothing moves.

Aluminum is pretty soft and carbide would mill it pretty easy. Expect to sharpen the bit afterwards.

10/19/17       #8: Hinge Boring for Aluminum Framed Do ...
Jarvis

I'm not sure if those hinges would even work in an aluminum door cause I don't think there will be anything to screw in to.


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