Woodhaven 8545: 4.5 Inch Hinge Jig User Manual

Page 2

USING THE JIG ON A JAMB WITH A STOP

If you are cutting a strike plate in a jamb with a door stop

and casing in place, you'll need a longer bit (PN 8505 Hinge
Bit, 3/4" cut length). You'll also need a wood fence that will
position the Hinge Jig at least 1/2" above the jamb and straddle
the casing. If your door stops are 1/2" thick, part of the Strike
Plate Jig will be supported on top of the door stop. If the door
stop is thinner than 1/2" you'll need to shim between the Strike
Plate Jig and jamb so it's at least 1/2" above the jamb. This can
be accomplished by using double stick tape to attach 1/2" thick
shims to the underside of the Strike Plate Jig. The 8505 Hinge
Bit will work on doors with stops up to 3/4" thick. See fig. 3.

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.

Install our the 8505 Hinge Bit (1/2" diameter with a

5/8" bearing and a 3/4" cut length), or a 1/2" bit (13416)
and 5/8" bushing (5030K), in your router. If using the 8505
Hinge Bit, make sure the bearing rides firmly on the edge of
the jig before attempting any cuts. Since the cutting depth
for hinges 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, 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. When you get to an edge, move clockwise,
following the edge of 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.

OPTIONAL ACCESSORIES

Self-centering drill bits (PN 6509 - 9/64", 6511 - 11/64" and

6513 - 13/64") are available to insure perfectly centered pilot holes.

A Corner Chisel (PN 8508) is available to square

the radiused corners left by the 1/2" router bit.

The Hardware Kit (PN 8510) and Double Track (72" - PN

4072 or 96" - PN 4096) allow you to attach up to three hinge jigs
to an aluminum extrusion for consistent and even hinge spacing.

(800) 344-6657 or WWW.WOODHAVEN.COM