Thingiverse
Door hinge mortise jig
di KD7LRJ
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Jig for cutting a mortise into a door or jamb to fit a 3 1/2" hinge with 5/8" corners using an offset router bit.
Here is the bit I used: https://smile.amazon.com/dp/B06WVDHM14 the cutter is 1/2" in diameter and the bearing is 5/8", so the jig compensates by adding a 1/16" offset to the edges so the jig doesn't get torn up.
My trim router is an older version of this one: https://www.harborfreight.com/power-tools/routers-cutout-tools-lathes/14-in-24-amp-trim-router-62659.html
Holes for holding the jig in place are 1/8" and I just used some M3x16 wood screws I had laying around. I could have made the jig shorter and sunk the screws below the top surface. Having it long seems to help get it straight. Not having alignment tabs to set the offset allows it to be tweaked if needed and makes it usable on the jamb as well as the door. Fusion360 source is included.
Here is the bit I used: https://smile.amazon.com/dp/B06WVDHM14 the cutter is 1/2" in diameter and the bearing is 5/8", so the jig compensates by adding a 1/16" offset to the edges so the jig doesn't get torn up.
My trim router is an older version of this one: https://www.harborfreight.com/power-tools/routers-cutout-tools-lathes/14-in-24-amp-trim-router-62659.html
Holes for holding the jig in place are 1/8" and I just used some M3x16 wood screws I had laying around. I could have made the jig shorter and sunk the screws below the top surface. Having it long seems to help get it straight. Not having alignment tabs to set the offset allows it to be tweaked if needed and makes it usable on the jamb as well as the door. Fusion360 source is included.
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