I come to you with a problem that has been plaguing me for awhile. I just completed another shaker clock, an exact copy from the popular woodworking magazine and I can't get the top door to stay closed.
I know that the door is flat and level because I made sure of it and just checked it 10 mins ago. The door is 10.5" wide by 11" in length. The hinges are no mortise style with the hinge being 2' long with a leaf width of about 3/4".
I use rare earth magnets 1/4" in diameter both in the frame of the door as well as the case. Now with the case laying on the workbench and the door laying in the proper position without the hinge, the pull of the magnets keep the door closed. I then attached the hinge to the door and with the part that should be attached to the case just loose on the case the magnets are still holding the door shut. The pull is fairly strong. The problem I have is that as soon as I attach the leaf of the hinge to the case the door won't stay closed when hanging on the wall. It will open about 1/8". I noticed the pull of the magnets isn't very strong when the hinge is attached to the case.
What I don't understand is why this is happening. Like I stated the door stays closed by the pull of the magnet without the hinge being attached to the case,but as soon as the hinge is attached to the case the door wants to open when the clock is hanging on the wall.
I don't have this problem with the bottom door, it stay shut all the time with the magnets. I have made sure that the screws attaching the hinge to the door and the case are not above the level of the hinge. They are countersunk slightly into the hinge.
Can anybody help me to trouble shoot this problem and correct it please? Could it be the hinges or something else? I can say that because of the glass the top door weighs about twice the bottom door which is the same width but about 20" length.
Your ideas would be a great help. Thanks