NOTE: For this project, measurements are up to you. Mine was definitely pocket-sized, about 3.5x1.5x1.5 inches in all, fully extended it was more like 5.5". That's awesome, but it's pretty bulky for what it is; I'd love to try this with a harder wood, at a smaller scale, and with more finite tools, and make it even nicer and more convenient to carry around. Anyway, here goes.
Step 1: Materials
Step 3: Cutting
Step 4: Planning & Marking Utensils
Step 6: Marking Utensil Shapes
Step 7: Shaping Utensils
Step 8: Hinge-Drill Prep
Step 9: Drilling the Hinge Hole
- Clamp everything onto scrap wood so you don't drill into your work surface.
- You can even gauge the depth of the drill by figuring out exactly how far in the bit will be when you're through your shell piece, and putting some masking tape right above it there, so when you're drilling down and you reach the tape, you're done drilling. That way you won't drill through your scrap wood.
You need to be drilling straight up and down, at a 90 degree angle to your piece. A drill press is key in this step, if you can find one. There are small portable ones that'll be just fine, probably running 20-40 bucks. You could even make one by Googling what they look like, they're not overly complicated. But in order for the hinge to work just right, the straighter of a hole as you can get the better.