Woodhaven 8545: 4.5 Inch Hinge Jig - Manual

BEFORE BEGINNING
Identify and verify that you have all the parts listed.
Read the instructions at least once before beginning.
ASSEMBLY
Cut a wood fence to mount the Hinge Jig to.
The wood fence should be approximately 3/4" thick, 1-
1/4" wide and 12" long. You can make the wood fence
longer if you want to mount more then one Hinge Jig to
a fence and cut two or more hinge mortises at a time.
Drill two 1/8" pilot holes in the edge of the wood fence 6-
3/8" on center. Mount the Hinge Jig to the wood fence using the
3/16" Washers (WS003) and 3/4" Screws (STP001). See fig. 1.
Place the 1/4" Spacers (BUSH002) on the 1/2" Thumb
Screws (5503) and screw them in to the two holes of the
Hinge Jig shown. The remaining two holes in the Hinge
Jig are for storing the thumb screws & spacers when not
needed. Place the Hinge Jig on the edge of the door so it's
between the two spacers and the wood fence, snug the wood
fence against the door and tighten the screws. This sets the
hinge backset 1/4" from the back edge of the door and insures
that the wood fence is square and parallel on the Hinge Jig.
Remove the thumb screws/spacers for jambs. See fig. 2.
The 1/4" margin is an industry standard, but you can
change it if desired. By adjusting the wood fence forward
or back in relation to the spacers, you control the forward/
back hinge position on the work. If a different backset is
needed, cut a 1/4" thick x 8" long spacer to the width required
to position the hinge in the desired location on the part.
USING THE JIG ON A JAMB WITHOUT A STOP
Mark the strike plate location on the jamb. The Strike
Plate Jig is 1/8" wider (1/16" on each side) then the actual strike
plate opening it cuts. Position the Strike Plate Jig so its edges
are 1/16" from the strike plate location marks, or make the
strike plate marks 1/8" further apart to correspond to the actual
opening in the Strike Plate Jig. Clamp the Strike Plate Jig to
the jamb using the wood fence and two clamps. See fig. 1.
8545
Hinge Jig
Please Read Carefully!
1
Parts List:
Part Description Quantity
8545 4-1/2" Hinge Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
STP001 #8 x 3/4" Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
WS003 3/16" Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BUSH002 1/4" Spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5503 1/2" Thumb Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1
2
Attach spacers here
Install our 8500 Hinge Bit (1/2" diameter with a 5/8" bearing
and a 1/4" cut length), or a 1/2" bit (13416) and 5/8" bushing
(5030K), in your router. If using the 8500 Hinge Bit, make sure
the bearing rides firmly on the edge of the jig before attempting
any cuts. Since the cutting depth for locks is shallow (usually
1/8" or less), either a standard or plunge router will work. Set the
cutting depth of the bit, taking into account the thickness of the jig.
Plunge or tilt the router bit into the approximate center
of the jig opening, moving in a small clockwise circle as you
do so to cut a relief opening. With the router base riding
firmly on the jig, move towards an edge of the jig opening.
Moving clockwise, follow the jig until the outline has been
cut. Make clean up passes to remove any remaining material.
After making the first cut, the wood fence will have a
cut out area that corresponds to the strike plate size. You can
use this cut out area to position the jig on the next parts.