One of the things the C/R is known for is making its own hardware. With that in mind, I set out to make my offset-knife hinges from flat brass and steel rod stock. I should mention that the set shown here is not my first set (that set now rightfully residing in the scrap bin.) Blanks are cut from 1/8" brass sheet stock, then filed to exact length.
Next, a small hold-down jig is used to drill out the pin- and screw-holes. Exact placement of these holes is critical, as four leaves (two for each pair, and two pairs to a door) will all have to line up if the door is to swing properly.
After drilling, each leaf is flattened, polished, and labeled (top right door, bottom left cabinet, etc.)
After the parts are labeled, each leaf is paired with its "mate" (one leaf to be installed in the cabinet, one leaf to be installed in the door). The pin holes are reamed to accept the steel hinge pin, then each pair is super-glued together for shaping.
Each rectangular pair is then filed into an "L" shape to offset the swinging action of the doors.
Once the hinges are shaped to final dimensions, they are pulled apart, and laid out to scribe the mortise each one will fit into.
After the mortise has been routed and chopped out, screw holes are located and carefullydrilled. Drilling through the piece would mean a bad day at the shop.
The hinge is pressed and screwed into place before glue-up, making installation significantly easier.