Installing Quadrant Hinges. Without a Router. At this point, I have all four mortises cut, and I'm satisfied with the depth of the hinge wings. We're now at the moment of truth - (1) will the hinges line up in the mortises?
James Dillon in MD Jim, My limited experience with quadrant hinges told me they are fussy to install, but doable. Using a router template makes the job easier to cut the hinge mortise. Having a drill press to drill out the mortise for the quadrant arm proved useful.You might also consider the Brusso lid support which only needs a 1/4 inch mortise and mimics in action the cloth you previously used. For your project, size is critical as you only have 7/16 inch stock to work with. I think the smallest Brusso quadrant hinge is 5/16 inch wide so that doesn't leave much room for error.
Brusso also makes a box hinge with a built-in lid support which I have used and it works fine (at least on 1/2 inch stock). I've used the router template(s) made by the Beall Tool Co. (along with their Hinge Wizard), with a downcut spiral bit in a laminate trimmer but you could fashion your own template. Beall too also sells a non-Brusso quadrant hinge (and template) that might be smaller in width.
Tools for Working Wood (a WoodCentral sponsor) has excellent pricing on Brusso hinges - especially for 4(?) or more. Lee Valley also carries a nice selection. I think the quadrant hinges are quite nice looking and worth the extra effort.
The CB-302S full mortise butt hinge, milled from stainless steel, is one of four different sizes manufactured for boxes and small cabinets. Stainless steel gives the hinge a modern look and does not tarnish, making it suitable for kitchen, bathroom, and marine applications. It measures 1¼' x 13/16'. Length: 1.250' - 1¼' - 32mm Width: 0.802' - 13/16' - 21mm Leaf Thickness: 0.086' - 5/64' - 2mm NOTE - All Brusso hinges come in PAIRS. Screws are INCLUDED (brass for the brass hinges and stainless for the stainless steel hinges). Routing template available: TJ-102.