I should know better, really I should. Time and again, I press forward only to run headlong into reality.
This week I’ve stolen only a few minutes away from work; or more accurately, work has stolen most of the evening hours from me. Those minutes that I could apply to the railway went to creating a plug to assist with positioning the doors so I can complete the hinges.
Having only a few minutes, I pretty much threw the doors on the plug and found to my chagrin that they are too big! How has this happened? The drawing actually allows .020″ (.5 mm) clearance around the doors. Yet, they are as much as .040″ (1 mm) too wide.
My best theory is that because I cut out the openings and the doors themselves in separate runs, the cutter is not as accurate as I might have hoped or thought. I don’t recall, but perhaps I even rotated one of the parts, and it is likely that the cutter is not uniformly accurate; a vertical centimetre may not be the same as a horizontal one.
In any case, now I am faced with a gut-wrenching decision. Should I salvage the hinges and abandon the doors, or shave little bits off here and there to see if I can make them fit?