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WHEN HANGING DOORS 7 TO 8 FEET TALL: The top of the top hinge may be located anywhere
between 7" to 8" from the top of the door. The bottom of the bottom hinge may be located anywhere
from 10" to 11" from the floor. Use long end gauge marked with 7" and 8".
DETERMINING HANDING OF DOOR
Either left or right hand doors may be routed. There are several ways to determine the handing of a
door. For our purposes, we use the visible hinge method. To determine a left-hand door or a right-
hand door, face the door opening from the side on which the hinge pins will be visible after door is
hung. If hinge pins are on the right, it is a right-hand door. If pins are to the left, it is a left-hand door.
POSITIONING DOOR FOR ROUTING
While facing the door from the side on which the hinge pins will be visible, set the right-hand door on
a long edge with the top of the door to the left. Set a left-hand door on an edge with the top to the
right. The hinge areas to be routed will face up. Secure door in this position by clamping to a sturdy
worktable or bench.
Laceration hazard. Do not attempt to use the router on an unsupported workpiece.
TEMPLATES, RAILS AND THUMB SCREWS NEEDED
FOR THREE HINGE DOOR: Three templates, two long rails (Part No. A07338), four large thumb
screws and six small thumb screws (if there is no stop in the door jamb area).
FOR FOUR HINGE DOOR: Four templates, three short rails (Part No. A16852), six large thumb screws
and eight small thumb screws (if there is no stop in the door jamb area).
ASSEMBLING TEMPLATE FOR RIGHT-HAND DOOR
For this section, we will describe how to set up the Hinge Butt Template for a specific situation. For
the example, we will explain how to mortise three hinges for a 1-3/8" thick, 6'8" right-hand door with
3½" long hinges that start 5" down from the top of the door. Our clearance between top of door and
jamb is 1/16".
NOTE: Change the measurements below to fit any specific situation.
1.
On each template section, loosen thumb nuts (A) Fig. 1 and adjust hinge size plates (B) so the
triangle indicators (C) align with the 3½" marks on the template body. Adjust all template sections
in the same manner. Be sure pin on bottom of hinge size plate engages hole in template body.
Tighten thumb nuts (A) securely.
2.
With left template section oriented as shown in Fig. 2, remove the left thumb nut and washer (A)
and install the 5" (or short) end gauge (E) as shown. Align the scribed line (F) next to the number
"5" with center of alignment pin (G). Use the end gauge that corresponds with where the top of
the hinge should be placed.
3.
Set the left template section on the top edge of the door on the left and snug template edge (H)
Fig. 3 against door. Place straight edge (I) on left edge (top) of door and slide the template over
until the end gauge 1/16" step (J) is against straight edge (I). Drive nails (K) into door.
4.
Attach the rail (L) Fig. 4 with rail adjusting thumb screw (M) to right end of the template section (N)
which has been nailed to door. Before tightening screw (M), adjust rail (L) so the 3½" graduation
line on the "5 TOP 10 BOTTOM" scale (as shown at (O), Fig. 4 inset), lines up with the end (P) of
template section (N).
NOTE: There are recesses (Q) Fig. 5 in the rail (L) for the 3½" hinge size. When sizing for 3½" hinges,
be sure the plunger in the thumb screw (M) Fig. 4 locates in the recess to help prevent movement.
NOTE: When the hinge size is something other than 3½", the plunger within thumb screw (M) retracts.
Care should be taken not to jar adjusting channel out of location.
NOTE: Use the scale for "7 TOP 11 BOTTOM" to locate the 3-1/2" mark (as described in Step 4) if
using the long end gauge.
5.
Line up the center template section (R) Fig. 7 so the end of the template lines up with the 6'8"
mark (T) on the rail that was just installed. Attach the template at this location using a rail adjust-
ment thumb screw (S).
NOTE: Recesses (U) Fig. 6 in the rails are provided for 6', 6'6", 6'8" and 7' doors. Tighten screw (S)
Fig. 7, being sure the plunger within the screw locates in the recess to help prevent movement.
NOTE: When mortising other size doors, the plunger within thumb screw (S) retracts. Care should be
taken not to jar adjusting channel out of adjustment.
6.
Snug template edge against door and drive nails (V) into door.
7.
Attach the next rail to right end of center template section as outlined in Step 4.
NOTE: When hanging a four-hinge door, two center templates will result, as shown in Fig. 9.
8.
Attach the right (final) template section to the door as outlined in Step 5. The door is now ready
for routing the hinge areas. (Final template sections should look like Fig. 9.)
ASSEMBLING TEMPLATE FOR LEFT-HAND DOOR
Here are the differences for setting up the template to route a left-hand door:
1.
Assemble template as outlined for right-hand doors but DO NOT DRIVE NAILS and DO NOT
INSTALL THE END GAUGE.
2.
Facing door, set the assembled Hinge Butt Template on edge of door. In the right template sec-
tion (W) Fig. 8, attach the 5" (or short) end gauge (X) underneath the right side thumb nut and
washer (Y). Line up the end gauge (X) so the scribed line (Z) next to the number 5 is in the center
of alignment pin (AA).
3.
Place a straight edge (BB) against the top (right end) of the door. Move template so that the 1/16"
step (CC) in the end gauge (X) is touching the straight edge and nail the template in place.
C
A
Fig. 1
Fig. 2
J
Fig. 3
B
A
O
T
SELECTING ROUTER BIT
Determine the size of the corner radius on hinges to be installed and select corresponding bit and
template guide. (See "HINGE CORNER RADIUS" section for guidance.)
To insure correct size mortise is cut it is important that only the template guide specified for the size
of bit selected be used. If hinges have square corners, the 1/4" diameter bit and corresponding tem-
plate guide are recommended. A corner chisel, to square the corners of cut mortise, is included for
this task.
PREPARING ROUTER
Read and follow the instructions in your router's owner's manual.
To reduce the risk of injury, turn router off and disconnect it from power source before
installing and removing accessories, before adjusting or when making repairs. An accidental start-up
can cause injury.
1.
Assemble template guide to router base with lock nut and tighten lock nut securely.
2.
Install selected bit in router collet and tighten securely.
3.
Set router on Hinge Butt Template and adjust depth of cut so bit just touches door.
4.
Set router depth adjusting ring to zero position.
5.
Lift router from template and adjust depth of cut equal to thickness of hinge to be installed.
6.
Firmly tighten motor locking device.
DOOR HINGE ROUTING
Before making any cuts, be sure to read the router owner's manual for safe operating
instructions.
1.
Connect cord to power source.
2.
Secure door by clamping to a sturdy worktable or bench.
Laceration hazard. Do not attempt to use the router on an unsupported workpiece.
3.
Start motor and place router on template and make first cut from right to left along outer edge of
door.
4.
Rout out remainder of mortise by moving router from left to right.
5.
When mortise has been completely cut, turn off router and wait for the motor to come to a com-
plete stop before moving the router.
6.
Rout remaining mortises in the same manner.
REMOVING TEMPLATE FROM DOOR
Pull the nails securing template to door by inserting the claw end of a claw hammer under nail heads,
one of which is shown at (DD) Fig. 8.
ROUTING JAMB WITH DOOR STOPS ALREADY IN PLACE
1.
Place assembled Hinge Butt Template up against door jamb so the end gauge (EE) Fig. 10 is now
touching the top of door jamb (GG) as shown.
2.
Hold template snug against the door stop (FF) Fig. 10 and up against the top jamb (GG) and drive
in nails, one of which is shown at (HH). To finish hanging the template, hold each remaining sec-
tion snug against door stop and drive in nails (not shown).
3.
Rout mortise in same manner as for door.
ROUTING JAMBS WITHOUT DOOR STOP IN PLACE
1.
Screw in two jamb stop pins (II) Fig. 11, in each template section in the correct holes (JJ) Fig. 12
N
M
P
Fig. 4
U
Fig. 6
S
V
Fig. 7
Fig. 8
L
Q
L
Fig. 5
R
W
DD
Y
Z
AA
X
CC
BB
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