I need to cut a section of piano hinge for a cabinet door, and the last time I did that the rod fell out. What should I do differently this time?

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HINGES.jpg
It took a couple of firm hammer blows on this pointed punch to form a dimple that holds the piano hinge rod in place.

Q:

I need to cut a section of piano hinge for a cabinet door, and the last time I did that the rod fell out. What should I do differently this time?
—Tom Lendway, Vadnais Heights, Minnesota

A:

If you look closely at the hinge knuckles, Tom, you'll see a dimple every few inches. The manufacturer adds these to put just enough pressure on the rod so it won't slide out. If you cut a piece so short that it contains no dimples, or maybe only one, use a small-diameter punch and a hammer to add a couple of dimples.