Patterns: We create paper patterns for our hinges that look like this:
They can be traced and then glued onto metal sheet and trials made until a final master is made which can be photocopied and copies pasted on metal and cut out or laser cut (we use Laser Precision Cutting). For this small hinge we used 18 gauge mild steel. The pin was made from a 16 penny box nail. We glued the pattern on the stock (rubber cement works fine), center punched for the screw holes and then cut out the hinge piece using an Edwards #1 shear, hacksaw and cold chisel. We cut the basic outline with the shear, then cut the barrel(s) with the hacksaw (make your cut on the waste side of the line). A cold chisel cut the waste piece between the two barrels after hacksaw cuts had been made.
Die: