DW. Just lost a long post, so will just summarise. I personally don't like the hinge on the "interesting" picture. It doesn't look quite right. Not taken with the piano hinge either, but just my opinion.
If the fitting/aligning of the hinges is causing issues that a jig cannot simplify, what about looking for a brass version of a wooden hinge (google images). I don't know if they exist, but a surface mounted decorative hinge would be very quick for a little job I have to make soon(ish).
Alternatively, what about barrel hinges http://www.romanys.co.uk/12-mm-barrel-h ... -489-p.asp.
As for the stained glass- I like that idea. Could you reverse paint a glass panel, and combine your other hobby?
If the fitting/aligning of the hinges is causing issues that a jig cannot simplify, what about looking for a brass version of a wooden hinge (google images). I don't know if they exist, but a surface mounted decorative hinge would be very quick for a little job I have to make soon(ish).
Alternatively, what about barrel hinges http://www.romanys.co.uk/12-mm-barrel-h ... -489-p.asp.
As for the stained glass- I like that idea. Could you reverse paint a glass panel, and combine your other hobby?