So I'm working on building a campaign style folding desk (specifically the one from Chris Schwarz's book). For anyone unaware of the basic design, imaging a basic table (four legs and aprons). The front two legs are attached to the front apron with typical M&T joints. Same with the back two legs and rear apron. The side aprons are actually four pieces (two on each side), with various hinges to allow the side aprons to fold in, which allows the base to collapse (making it easier for travel).
I'm having ...issues... with the hinges. Specifically with screws breaking when trying to install the hinges. Brass hinges with brass screws (both from Lee Valley, so quality should be good). I know brass is a bit more of a delicate metal, and I broke one screw when doing a test joint. So I decided to run to the hardware store and buy some wood screws from there (same thread pattern), figuring that I could drill the pilot hole, use one of these screws, then back it out and use the brass one as the final (figuring this would put less stress on the weaker screw). This has been a disaster. I've broken three of the screws (out of 6 for the first hinge). One of the three broke far enough down that I was effectively able to drill it out. The other two are stuck.
I think part of the problem is that I went with longer screws than called for (1.5" instead of 1"), figure this would hold better, and the screws end up being structural (two of the hinges are in end grain, including the first one I've been trying). The wood is soft maple, and I'm actually using larger than typically what one would use for a pilot hole. (I initially tried a smaller pilot hole (3/32), and when the first screw sheared I increased the size of the pilot hole. I'm up to 1/8" and still having this issue).
Any suggestions? I'm about at the point where this is going to just be a desk instead of a folding desk (I've got some extra lumbar left over and could just cut out two aprons and attach them to the side via dominoes). I could use that extra lumbar to remake the two aprons that have screws stuck in them so far, but that is an involved process and also includes roping in a friend to help (which I would prefer not to do). I'm also not sure how much my daughter cares about the folding feature (going to ask her later today).
But this still doesn't stop the problem I'm having of shearing screws off when installing hinges. I've had this happen before. Any suggestions? Better wood screw to use as the first/lead screw before using brass? (I'm sure the one I got from the hardware store isn't the best quality). What else? I'm driving the screws with a screwdriver and pausing every once in a while to allow heat to dissipate.
