Rockler JIG IT User manual

JIG IT®Hinge Mortising
System Instructions
With templates for specific quadrant and side-rail hinges, bits and guide bushings (all sold separately)
the JIG IT Hinge Mortising System allows you to use your plunge router to easily cut precise mortises
for jewelry boxes, humidors and other small boxes. For safe and effective operation, please read these
instructions fully before use.

2
Quantity
1 Jig Base 1
2 Fence 1
3 Front Spacer 1
4 Optional Rear Spacer 1
5 8-32 Flat Head Socket Cap Screws 4
6 4mm Flat Washers 2
7 8-32 Socket Head Cap Screws 2
PARTS LIST - DRILL PRESS FENCE
6
2
13
5
4
7
Etched line

3
Jig Setup
We strongly recommend that you familiarize yourself with the
jig and setup process before attempting to rout mortises in your
finished project. You can do this by positioning the jig and making
practice cuts on scrap boards clamped to a workbench or table or
on a test box and lid.
1. Assemble the jig as shown in the exploded view. Do not
overtighten screws used to attach the Front and Rear Spacers.
Leave the Socket Head Caps Screws in Fence loose.
2. Orient your box and lid as if in the fully open position.
Make appropriately sized spacer blocks and/or use Bench
Cookie®Plus Work Grippers (46902, sold separately) under
the lid to bring it level with the box. On both lid and box,
mark a centerline along the top edge of the side where the
hinge will be installed. Fig. 1.
3. Position the jig on the box and the lid with the Front Spacer
in the middle to ensure that they’re the correct distance
apart. Make sure that the sides of the box and lid are aligned
and ensure the the box and lid are flush vertically against the
underside of the Jig Base. Clamp the fence to the lid and box.
4. Slide the jig Base to line up the etched marks at its edges with
the centerlines on the box and lid. Fig. 2. Double-check the
alignment, then use the included hex wrench to tighten (but
not overtighten) the Socket Head Cap Screws to lock in the
Base and Fence. Clamp the box and lid at the Front Spacer,
and add another clamp across both assemblies to ensure the
Front Spacer is tightly sandwiched between the box and lid.
Fig. 3. Double-check the alignment to be sure everything
is square.
Note: If the alignment is off, the hinges will not be parallel
to the sides and might not function properly. Once the jig is
set correctly, it can be used on any box made from the same
thickness of stock.
Jig Use
Detailed instructions for individual Templates are available
at Rockler.com
1. Choose the appropriate Template (sold separately) for the
hinge you are installing and insert it in the opening in the Jig
Base, making sure to align the letter “A” on the Template
with the “A” on the jig. Fig. 3.
2. Install a 3/16" straight router bit (90000, sold separately) and
a 3/8" O.D. guide bushing and locking nut (43877 and 63107,
sold separately) in a plunge router.
3. Set the cutting depth to a hair less than the hinge thickness.
To do this, place the router on the jig with the bushing in the
“A” cutout and — with the router off — slowly plunge until
the bit just makes contact with your box. Engage the plunge
lock. Place a leaf of your hinge under the router’s depth stop
and lower the stop until it contacts the hinge.
Note: Make test cuts on scrap to verify the depth setting. The
hinge needs to sit flush or slightly proud, or the box lid might
not close properly.
4. Double-check that the Template is positioned correctly on the
jig, then make the plunge cut in “A.” Use the bushing to follow
the edges of the cutout, and rout away any material left in the
middle. When finished with the cut, release the plunge
mechanism and allow the bit to stop spinning before lifting
the router from the jig. If your Template has no other labeled
cutouts, you are done on this side of your box. Fig. 4.
Fig. 4
Fig. 3
Fig. 2
Fig. 1
Align “A” letters
“A” letters aligned

4Distributed by Rockler Companies, Inc.
©2015 Rockler Woodworking and Hardware
58822
Rev 09/15
Important Safety Instructions
1. This tool is designed for specific applications as defined in
the instructions and should not be modified and/or used for any
other applications.
2. Before using the Rockler Hinge Mortising Jig It read, understand
and follow all instructions and safety information provided.
3. Always read, understand and follow the instructions and safety
warnings for any tool that is used in conjunction with this product.
4. Before using this product, review and verify that all tools used
with it are in proper working order as defined by the tool’s
owner’s manual.
5. All safety equipment must be installed and working properly
as defined by the tool’s owner’s manual.
6. Do not use this product until you have read the provided
instructions and warnings and are confident you understand them.
7. Always wear safety glasses in compliance with ANSI safety
standards and hearing protection and follow all standard
shop safety practices including:
A. Keep your work area well lit and clean.
B. Use dust collection tools and dust face masks to reduce
exposure to dust.
C. Keep children and bystanders away while operating your tools.
D. Maintain proper footing at all times and do not overreach.
E. Do not force the tool.
F. Unplug all power tools before making any adjustments
or changing accessories.
8. Remain alert and use good judgment when using this tool. Do
not use this tool if you are in any way impaired by medications,
alcohol, drugs or fatigue.
9. Dress appropriately and remove all jewelry, secure loose
clothing and tie up long hair before using this tool.
10. It is the sole responsibility of the purchaser of this tool to ensure
that any third party reads and agrees to all the safety precautions
outlined in this manual prior to using the tool.
11. Maintain these instructions and warnings as long as you own
the tool. Keep in a place where they will be readily available
for reference.
12. The user assumes all risk for the proper use of this tool and
for ensuring product suitability for intended application.
13. These warnings and instructions do not represent the total of all
information available regarding tool safety, use and technique.
Always seek out opportunities to learn more and improve your
skills and knowledge.
14. Secure your workpiece to the work surface and clamp the
Hinge Mortise Jig It to the workpiece with clamps before
attempting to make any cuts.
15. Maintain awareness of the router bit at all times while cutting.
Check Rockler.com for updates. If you have further questions, please
contact our Technical Support Department at 1-800-260-9663
or [e-mail]
Hinge Installation Tips
• To avoid stripping or breaking soft brass hinge-mounting
screws, drill pilot holes and, if possible, tap the holes with
a steel screw of the same size and thread specifications.
• If the installed hinge won’t close completely, verify that the
mortise for the lid support (if there is one) is deep enough
and that the hinge is flush or slightly proud of the surface.
If you cut the mortise too deep, small strips of tape can
be used to shim it up to the proper height.
5. If your Template has a “B” cutout, rotate the Template to align
with the “B” on the jig. Make the plunge cut. If your Template
has no other labeled cutouts, you are done on this side of your
box. Fig. 5.
6. If your Template has “C” cutouts, rotate the Template again.
For these cuts, unlock and retract the depth stop to allow a
full-depth plunge cut. But don’t try to plunge all the way in
one cut; make a series of successively deeper cuts. Fig. 6.
Note: You will need to extend these mortises by drilling.
Tips on completing this operation are included in online
instructions for the appropriate Templates.
7. Carefully clean out the deepened mortise with a chisel if
needed. Do not drill or chisel outside the routed edge of the
mortise, or the hinge will not fit well. Be careful not to put
too much pressure on the mortise walls; they could break.
8. Sand and/or add shims to achieve desired fit and appearance.
9. Repeat process for hinge on other side of box.
Fig. 5 Fig. 6
“B” letters aligned “C” letters aligned