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
Fig 02
Template
Hinge
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