Is there any rule of thumb regarding sizing of door hinges? When does one need more than standard weight 3.5 X 3.5 inch butt hinges? If the door weighs more than 50 lbs? How about wider than 32 inches? Does one go up to a 4 X 4, or 4.5 X 4.5, or use heavier gauge steel or brass (.130 inch)?
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If you have a Grainger catalog, a chart's there for Stanley hinges. In addition to weight, it includes frequency of use and door thickness, not width.
I've been known to swing several hundred lb doors and went to ball bearing hinges very successfully. My local lumber yard tried to tell me I just needed an extra 4 1/2" hinge and refused to order the ball bearing ones. It would have worked for a little while.
PAHS Designer/Builder- Bury it!