RoutingJigs Adjustable Hinge Jig Manual

Adjustable Hinge JigAdjustable Hinge Jig
AdjustableAdjustable
50mm - 127mm
(2” - 5”)
6.5 - 35mm
Hinge sizes possible
nThree adjustable hinge apertures.
nFor hinges 50mm(2”) - 127mm(5”) x 6.5mm - 35mm.
nComes in two parts for easy storage.
nBased on a 2 metre door, the hinge positions are 6” from top, 9” from base, and middle.
nEnd datum stop to control the 3mm gap between the top of the door and frame.
Other Equipment required:-
n12mm diameter straight cutter.
n16mm diameter guide bush.
nAt least two bradawls to secure jig to door/frame.
nPhilips screwdriver to adjust hinge apertures.
Instruction LeafletInstruction Leaflet
A sliding plate allows hinge
length adjustment.
Engraved marking allows
easy hinge measurement
and setting.
The depth of the
hinge can easily be
set. The hinge sits
in place within the jig
and the depth datum
is adjusted to suit.
The depth datum
butts up against the
door or frame to
control the depth of
the hinge.
A datum end stop
provides accurate
hinge positioning on
the door and frame.
Connecting Plate

Adjustable Hinge Jig
1. Assemble the Hinge Jig1. Assemble the Hinge Jig
The two individual parts assemble together by a
connecting plate. Use the keyhole slot to capture the
head of the screw and pull both parts of the jig together
in the direction shown in the diagram. Tighten the
screw to secure the jig together.
Assemble the 3 pairs of aluminium bushes onto the jig
if not done so already. There are 3 slots within the jig
which they screw onto and slide on.
Keyhole slot
2. Set up the Hinge Length2. Set up the Hinge Length
1. To adjust the length of the aperture the engraved
markings are used.
2. Loosen the screw so that the adjustment plate is
free to slide.
3. Align the leaf of the hinge with ‘0’ as shown in the
photo left.
4. Slide the adjustment plate so that it touches the
edge of the hinge. Tighten the screw to secure the
adjustment plate in place.
5. Repeat this operation for the other 2 hinge
apertures.
NOTE: If the length setup was done correctly then
the length of the hinge aperture on the jig should
be 4mm longer than that of the hinge itself. This is
because of the guide bush and cutter offset -
please see diagram below.
Adjustment Plate
Screw
Hinge Leaf
Align the edge with ‘0’
2mm
12mm cutter
16mm
Dia bush Adjustment Plate
Jig
2mm
Actual Hinge Size

Adjustable Hinge Jig
3. Set up the Hinge Depth3. Set up the Hinge Depth
1. Loosen the depth datum by hand by turning(do not
need to use a hex key)
2. Place the knuckle of the hinge in the slot as shown
in the diagram, and push in the direction shown.
3. Move the depth datum so it butts up against the
edge of the hinge.
4. Tighten the depth datum by hand by turning
clockwise.
5. Repeat this sequence for all three apertures.
Depth Datum
Slot
Hinge Knuckle
Push against
edge of slot
4. Rout hinge Recesses in Door4. Rout hinge Recesses in Door
1. Lay the door down on its front edge and secure in
position.
2. Loosen the screw securing the datum end stop and
rotate 90 degrees - as shown in the photo left.
3. Tighten the screw to secure datum end stop.
4. This hooks over the top of the door and positions
the hinges in the correct place. Make sure the end
stop is pushed against the top of the door.
5. Make sure all three depth datum bush’s are against
the opening face of the door
Datum
End Stop
Depth Datum
Bush
Jig
Door

Adjustable Hinge Jig
Rout hinge Recesses in Door cont...Rout hinge Recesses in Door cont...
6. Secure the jig to the door with bradawls.
7. Set your router to the depth or slightly deeper than
the hinge - refer to your routers manual for
instructions on how to do this.
8. Continue to rout the three apertures into the door.
9. Remove the bradawls and remove the jig from the
door.
10 Chisel the corners of the recess to fit the hinge.
5. Rout hinge Recesses in Frame5. Rout hinge Recesses in Frame
11. Loosen the screw which secures the end stop.
12. Turn the end stop back 90 degrees so that it is in
line with the jig. Tighten to secure in place.
13. No further adjustments are needed for the frame.
14. Use the opposite side of the jig for the frame - the
side which was face up when routing the door, is
faced against the frame.
15. Butt the jig up inside the frame as shown on the
photo left. The end stop will shift the hinge
recesses down by 3mm - this will give a 3mm gap
between the top of the door and frame.
16. Make sure the depth datum bush’s are against the
open side of the frame
16. Locate the bradawls.
17. Continue to rout the recesses for the hinges.
Bradawl
End Stop