re: My New Series Dr Who Tardis Build (image heavy)
When I left off last I was working on a problem mounting the sign boxes as there wasn't enough room to do it the way I originally planned, which was to use passageway door pin hinges as angle brackets that could be separated by removing the pin. This is how the show prop is made.
Instead, I decided to still use hinges, but in a more traditional manner. Unfortunately, it is much more difficult to do it this way, especially since the sign boxes are already assembled. Further, it also requires a much more precise layout to ensure everything lines up.
Since I was now going to mortise the hinges far into the ends of the sign boxes there wasn't enough wood there to fix the hinges to. First step was to back them up with another 3/4" piece, which I cut from oak for strength.
I then assembled a template to use for routing out the mortise with a bearing guided pattern bit, as before. Since the hinge has to stand away from the post for removal, I cut a 1/4" piece of acrylic as a spacer.
Next step was to carefully lay out the first sign box between two columns. I did this with all the pieces laying on the floor to make it easier to figure out the process the first time.
This is what the first hinge looks like mounted on the post.
And then here is the installed sign box mounted to the hinge. I'm happy to see it fits and is in the correct place.
I then cleared out a space in the shop to assemble the Tardis for further installation of the other sign boxes. As this isn't the most precise wood to work with, I felt I better do the rest of them in place just in case there were issues with slightly twisted posts or sign boxes. I noticed when I put the floor inside the base that the frame has already moved around a bit, with one side of the floor needing to be knocked into place in the floor.
Putting the sign box in place was somewhat cumbersome to do by myself. I'd definitely want help if I could get it for assembly and disassembly in the future.
First sign box installed.
Spacer plywood used for squaring the posts in place and a long clamp holding it all together.
Sign box sitting on the clamps for hinge location marking.
And the second sign box installed.