Complete Hinge and Door Hardware Forging: From Bar to Swing
Door hardware is essential for every building. This campaign covers hinge forging, latch making, lock mechanisms, and installation.
Chapter 1: Hinge Types
Type
Complexity
Strength
Use
Decorative Potential
Strap hinge
Low
High
Gates, barn doors, heavy doors
High
Butt hinge
Moderate
Moderate
Interior doors, cabinets
Low
Pintle hinge (pin and eye)
Low
Very high
Heavy gates, shutters
Moderate
T-hinge
Low-moderate
High
Shed doors, chests
Moderate
Butterfly hinge
Moderate
Moderate
Cabinets, light doors
Very high
Piano hinge (continuous)
High
Very high
Lids, long edges
Low
Chapter 2: Strap Hinge Forging
Strap hinge forging: 1) Start with flat bar (1/4 x 1.5 inch, 12-18 inches long for each leaf). 2) Heat one end of first leaf to bright orange. 3) Forge eye (barrel): wrap heated end around mandrel (3/8 inch rod). 4) Weld eye closed (forge weld the overlap). 5) Flatten and shape leaf (taper, decorative end). 6) Punch mounting holes (3-4 holes per leaf). 7) Repeat for second leaf (eye wraps opposite direction). 8) Make pin: straight rod that fits through both eyes. 9) Peen one end of pin to prevent removal. 10) Assemble: thread pin through both eyes.
Component
Stock
Finished Size
Forging Steps
Leaf (door side)
1/4 x 1.5 inch flat bar
12-18 inches long
Eye, flatten, taper, punch holes
Leaf (frame side)
1/4 x 1.5 inch flat bar
4-6 inches long
Eye, flatten, punch holes
Pin
3/8 inch round rod
Length of combined eyes + 1/2 inch
Cut, peen one end
Chapter 3: Latch Forging
Latch Type
Complexity
Security
Use
Thumb latch (Norfolk)
Moderate
Low (privacy only)
Interior and exterior doors
Slide bolt
Low
Moderate
Gates, interior doors
Hook and eye
Very low
Very low
Gates, shutters
Ring latch
Low-moderate
Low
Historical doors
Hasp and staple
Low
High (with padlock)
Sheds, chests, gates
Thumb latch (Norfolk latch): 1) Forge handle plate: flat bar with decorative shape, 8-10 inches long. 2) Forge thumb piece: lever that passes through door. 3) Forge latch bar: flat bar that lifts to open, drops to close. 4) Forge keeper (catch): U-shaped bracket on door frame. 5) Assembly: thumb piece lifts latch bar when pressed; gravity drops latch bar into keeper when released. 6) Punch mounting holes in handle plate. 7) Rivet thumb piece pivot to handle plate.
Chapter 4: Lock Mechanisms
Lock Type
Security
Complexity
Historical Period
Warded lock
Low-moderate
Moderate
Medieval to present
Lever lock
Moderate-high
High
18th century to present
Pin tumbler
High
Very high
Ancient Egypt, modern
Padlock (warded)
Low-moderate
Moderate
Medieval to present
Simple warded lock: 1) Lock body: forged box (2x3x1 inch). 2) Bolt: flat bar that slides in/out of lock body. 3) Wards: fixed obstructions inside lock body. 4) Key: flat key with cuts matching ward positions. 5) Spring: leaf spring that holds bolt in locked position. 6) Key turns, navigates past wards, pushes bolt against spring. 7) Bolt retracts, door opens. 8) Remove key, spring pushes bolt back to locked position.
Chapter 5: Installation
Hardware
Mounting Method
Fastener
Alignment Critical
Strap hinge
Lag screws or through-bolts
5/16-3/8 inch
Yes (pin must be vertical)
Butt hinge
Wood screws in mortise
#10-#12 screws
Yes (leaves must be flush)
Thumb latch
Through-bolts or screws
1/4 inch bolts
Yes (thumb piece must clear door)
Slide bolt
Screws
#10-#12 screws
Yes (bolt must align with keeper)
Hasp
Screws or bolts
#10-#14 screws
Moderate
Reference Card
The eye must be round and tight (the barrel of a strap hinge must wrap smoothly around the pin with no gaps; a sloppy eye makes a wobbly, squeaky hinge). 2. Forge weld the eye closed (an unwelded eye opens under load; forge welding the overlap creates a permanent, strong barrel). 3. Pin alignment is everything (both hinge eyes must align perfectly so the pin slides through smoothly; misaligned eyes bind and prevent the door from swinging). 4. Gravity is the latch mechanism (a thumb latch works because gravity pulls the latch bar down into the keeper; the thumb piece lifts it against gravity to open). 5. Punch holes before hardening (mounting holes must be punched while the metal is hot; trying to drill hardened steel is extremely difficult). 6. A hasp needs a padlock (a hasp and staple provide no security without a padlock; the hasp holds the door closed, the padlock prevents the hasp from being lifted). 7. Three hinges for heavy doors (a door over 6 feet tall or very heavy needs three hinges; two hinges on a heavy door will sag and bind). 8. The blacksmith makes the building functional (without hinges, latches, and locks, a building is just walls and a roof; hardware makes it livable and secure).
