Thread: Fitting Hinges

Hi Rick,

Rockler have a jig for hinges. Shouldn’t be too difficult to knock up something similar:

JIG IT(R) Hinge Mortising System | Rockler Woodworking and Hardware

Here’s the YT video. Doesn’t need to be this complex if you’re only using one type of hinge.

Rockler Jig-It hinge mortising system - YouTube

Good luck!

Brian

Hi Rick, I'm sure you'll get some other replies, but thought I'd give you my 10 cents worth.

The easiest and most accurate way to cut hinge mortises with a hand held router is to use a home made template and template guide bush. You will need a base or insert for the router that takes standard Porter Cable guide bushes. There are various options of guide bush, cutter and template sizes that will work, but for an 8mm (5/16") mortise I would suggest that a 1/8" cutter, 5/16" bush and 1/2" width template should be used. This will involve the minimum expense for purchase of items you don't already have.

Make your template from a piece of 9 or 10mm MDF. The piece should be big enough to allow you to easily clamp the template to your box while allowing adequate space for the router base to rout the mortise. Cut a 1/2" slot near the corner of your template board using your router and a 1/2" bit or your table saw. The length of the slot is not important provided it is at least, say, 50mm (2") long, but it is critical that the slot is 1/2" wide. The end of the slot needs to be round to ensure you cut a rounded end mortise. Clamp the template to your box, fit your router bit, base and guide bush to the router, set the depth of cut and rout your mortise. Practice on a piece of scrap first to ensure you have the placement of the template correct and feel comfortable completing the mortise.

The base or insert that you buy will depend on the router or trimmer you intend using. Sets of template guide bushes are available for Makita plunge routers with an adaptor insert included in the set. Some trim routers have bases that take guide bushes directly. If your router has a 35mm OD, 30mm ID apature in the base it will take guide bushes. Ensure you buy a set of imperial bushes, not metric.

If you Google 'using router template guide bushes' you will find articles and videos that will give you a better understanding of their use.

Hi Rick. I made a jig out of a scrap piece of wood. I'm using a 1/4" spiral bit with a spacer bushing in a small router. Figured out how much bigger the notches in the wood needed to be to account for the difference between the bushing and the bit and cut the notches on my table saw using a flat topped blade. Ended up with a flat piece of wood about 8" long with two identical notches for the hinges and a center mark inked in the middle of the scrap. I use 3M double-sided tape to hold the jig onto the edge of the box and route the hinge pockets. Then I transfer the jig to the box lid and repeat the process. I find the tape is still sticky enough to do both pieces with no problems. Still have to clean up the corners with a chisel, but that's done quickly. By using the same jig for both the box and the lid and referencing off the centers, everything always lines up perfectly. I used hardwood for my jig as I use the same hinges a lot so have used the jig dozens of times without worrying about wear. I have found you don't need a plunge router because you are going at the pockets from the sides. Best of luck!

box26.JPGbox27.JPGbox28.JPG

I forgot to add that with Spotted Gum you should wipe down with acetone prior to glue up.

Originally Posted by aldav

... Practice on a piece of scrap first to ensure you have the placement of the template correct and feel comfortable completing the mortise. ... ​

Aldav meant to say:
Practice on a piece of scrap first to ensure you have the placement of the template correct and feel comfortable completing the mortise.


This is critical. A router can do a lot of irreversible damage very quickly.

Thanks for the replies,
The wiping with acetone was what I could almost remember, now I know for sure, one other thing I have almost remembered is with mitred corners on boxes is to size? the end grain with glue and when nearly dry add more glue and clamp, not over tight. I will be using Tight bond 2 premium, should be ok with the spotty?
I think I miss the good old days when aquadhere glued everything.

Thanks Rick