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I did just that on my vice using a hammer. But the custom crank is slightly skewed. Hard to tell by eye but obvious when put against the frame. Not sure I can go down that route and not spend £100 on hinges till I get 3 right!

More feedback and engagement that I would have ever hoped for. You are are too kind. Love the dowel technique! That would have solved a lot of my problems if I knew about it from the start. I could even have used normal butt hinges, which come in nicer designs. Would that I knew, would that...

Thanks for all the suggestions! Got a lot of options here. Doug : I did consider these but we really wanted the butt-hinge look on the outside. Plus, it feels like I'm cheating :) Sgian: Will teach me to only shop from big name physical DIY stores. Should had looked at specialist websites...

The issue will only become worse if the door thickness increases. You are right in observing that the "excess" is consistent around the 3-4mm mark (edit: I measured since and it's actually 5mm). As I fitted them, the only way this door face would sit flush is if it was 15mm thick or under...

Thanks Andy! I managed to edit the original and added some images

Hi all, I woke up one morning, just a short year before turning 40, and thought it was about time I picked up a craft and put my empty garage to good use. So off I went and got me some tools and some MDF boards and some looks of pity from the tradesmen behind the counter (oh look at the desk...