The hinge cutouts were made using a Major Manufacturing HIT-45TG3 and a 1/2” router bit. The HIT-45TG3 is a 5/8” (outer diameter) template guide for use with my Sears Craftsman Fixed Base Router. The template is secured to the base plate with three included Phillips head screws. The router bit is a 1/2” straight cutting bit having a cut length of 25/32”. The router uses a 1/4” diameter shank.
I purchased a Milescraft Hinge Mortise Guide Set, part number 1297. The Hinge Mortise Guide Set is used with a router equipped with a 5/8” template guide and 1/2” straight bit, to make mortises for 3”, 3-1/2” and 4” hinges. This Guide Set can cut large 5/8” and small 1/4” radiuses for radiused hinges.
Note: Using a router and template guide saved a significant amount of time.
Basic router rules:
· Always wear ear and eye protection.
· Before making any adjustment, always unplug the router.
· Always cut in a clockwise direction.
· Feeding the router too fast or with too much cutting depth can splinter the wood. Wood will show burn marks.
· Never reverse direction when operating a router.
· Always wait until the cutter stops turning completely before removing the router from the template.
· Make a second pass to ensure a clean installation.
Install the template guide onto the router and insert the cutter. Mount the hinge mortise guide with the 3-1/2” insert onto the original door. Adjust the cutter until it just scrapes the hinge cutout. making sure that at least three-quarters of the cutter shank is within the collet. Tightened the collet to the cutter and tighten the adjustments for the router.
Reposition the hinge mortise guide on the door edge, and mortise out the opening. Next, remove the hinge mortise guide and place a hinge into the opening. The newly mortised opening was at the proper depth as the hinge body was level with the door edge.
Install the hinge mortise guide positioning the guide to accommodate the direction of the hinges. Route the two hinge openings in the six-panel door.
To simplify the installation of the hinges in the door, use a Major Manufacturing MCD-9, a 9/64” diameter center drill designed for #8, #9 and #10 screws. The center drill slides against each of the screw holes in a hinge and centers the drill bit to create the pilot holes in the door and jamb. For this installation, only the door needed pilot holes.
The hinges were mounted onto the door, making sure the hinge pins were located towards the top of the door. The hinges were then mounted onto the jamb. The door would swing open and closed with no obstructions. The door fit the jamb evenly with approximately 1/8” openings on the jamb side and a 3/16” opening on the header. The floor opening was approximately 3/4” as the floor was tile.
For this article, we installed a Schlage Accents Champagne leverset in the Satin Nickel finish onto the primered door. This “F” series passage latch adjusts to fit standard door preparations. Even though the Champagne levers are handed, they can be removed and reversed in order to accommodate any door configuration.
The Schlage leverset was installed using the Pro-Lok Killer Jig, part number INJIG-KJ. The Killer Jig is designed to install cylindrical and tubular locks into wood swinging doors. The jig is designed for 1-1/2” and 2-3/8” diameter cross bore opening with a 2-3/8” or 2-3/4” backset, having a one-inch edge bore opening.
Note: The lock hardware will have to be removed from the door when it is painted the finish color.
The fit and appearance of the six-panel door and leverset significantly improved the overall features of the area. As a result of this door installation, the interior doors of the residence will all be replaced with six panel doors and new locks.
To enable this installation, the following items were used:
• Six panel-door, for this applications, the door width was 24”
• Major Manufacturing HIT-45TG3 - a 5/8” outer diameter template guide
• Major Manufacturing MCD-9 - a 9/64” diameter center drill for #8, #9 and #10 screws
• Milescraft Hinge Mortise Guide Set, part number 1297 - mortising guide for 3”, 3-1/2” and 4” butt hinges
The solid construction of the Pro-Lok Killer Jig makes it a versatile cylindrical/tubular lock installation kit.
This modification provided the capability of a deadbolt and dead latch in one lock (mortise) mechanism while maintaining the integrity of the door.