TLDR: how to make a hole with a small
tooth guide key, i.e. with a section like the inside of a 'power on' symbol
Long read. I am trying to replicate a molded plastic hinge in wood. It is a hinge with a twist, in that it is intended to drive/rotate the
slotted keyseated shaft that slots into a 1x1mm key on the inside of the 9mm hole.
Longer read. It may sound ridiculous and definitely like a waste of time, but I am sorry to throw out a toilet seat by Ikea which has lived longer than any in the house. It is detachable and the hinges are in plastic and do not suffer corrosion. It is an over-engineered design that, AFAIK, is out of production. I have not found anything similar as a replacement.
I have a working solution, certainly not elegant. It was made by drilling an 8mm hole, digging out two channels around the key using a Dremel and long carving bit, with some help from a penknife and a small round file, and widening the sides of the hole.
I thought about making a 9mm hole and digging out a 2x1mm keyseat to fill with a 3x1mm key, but making the key and keyseat is just as much of a challenge. I also thought of using 1mm grub screws for the key.
Oh, and of course, just drilling a 9mm hole. Too easy of course :-).
What are your suggestions?