Using the Template
4
Using the template to cut 100mm
hinge recesses in the door edge
1.
The template is first adjusted to position the hinge
knuckle or pivot pin on the door edge to ensure that the
door will close correctly to the doorframe. The inside edge
of the template is set to the width of the hinge flap plus
the guide bush margin, see fig 01. The guide bush margin
is simply the difference between the cutter diameter and
the outside guide bush diameter, divided by two. Using
the suggested 26mm guide bush and a 20mm cutter, the
margin will be 3mm. As the template opening is 106mm,
using this combination will leave a recess length of 100mm
or the length of the hinge. Imperial 4inch long hinges will
require a 25mm guide bush and the 20mm cutter.
2.
Mark out the centre line of the hinge positions on the
door edge, see fig 02. Clamp the box section of the jig, with
the open edge of the template on the hanging (i.e. pivot
edge) face of the door, see fig 03. Align the engraved centre
line on the template with the hinge centre line marked on
the door edge.
Check that the template edge is square to the door face
before tightening the locking knobs. Do not over tighten
as this may damage the template.
NOTE. This formula can be used to calculate any recess
length to accommodate variations in the hinge length.
For example a 75mm hinge recess cut using the 106mm
template will require a guide bush diameter of 40mm
and a cutter diameter of 9mm. 106 - 75 = 31. Using a
40mm guide bush = 40 - 31 = 9mm diameter cutter.
Fig 01
Template
Hinge
Fig 02
Marking out the centre line of the hinge positions on
the door edge
Fig 03
Clamping the box section of the jig
3.
Fit the correct diameter guide bush and cutter to the
router to achieve the length of recess to suit the hinge, see
fig 04. As the template thickness is 6mm, the guide bush
depth beneath the router base must be slightly less than
this.
Centre line
