Major Manufacturing Hit-42FB8 Flush Bolt Jig

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Aanodized aluminum jig prepares wood doors for installation of Ives automatic flush bolts.


Securing each door of a pair of standard doors is accomplished using several different methods. The most common method is to use a concealed or surface vertical rod exit device on each of the doors. This way, a vertical rod exit device secures each door individually. When one door is opened, the...


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Before starting the installation, make sure all door hardware is in proper working order, and the doors swing smoothly when opening and closing.

For this article we installed an Ives FB41 automatic flush bolt into a 1-3/4" thick door section, using the Major Manufacturing HIT-42FB8. The Ives FB41 is designed for installation into a wood door having a minimum thickness of 1-3/4".

Step 1. Carefully lower the door to the floor with the swing side of the door facing up. Secure the door.

Step 2. Draw a depth line onto the door to provide reference for bottom of cutout.

Step 3. Mount the HIT42FB8 to the swing edge of the door at either the top or the bottom corner. The jig needs to be secured to the door using either a wood or drywall screw along the top or bottom of the door, and a spring or C-clamp to secure the jig to the swing edge of the door. This way, the installation will be clean.

Step 4. With the template removed from the jig, machine out a 1/8" deep opening to accommodate the guide and the faceplate from the door edge and top or bottom. A sharp cutter will ensure a clean cut. For safety's sake, always wait until the cutter stops turning before lifting the router off the jig.

Step 5. Attach the template to the jig using the supplied Phillips head screws.

Step 6. Adjust the plunge router base to a maximum depth of 2 inches.

Step 7. Set each pass at 3/16" depth of cut. If the door is manufactured from hard wood, consider setting each pass depth at 1/8". Always wait until the cutter stops turning before lifting the router off the template. Once the completed, remove the jig and clean the machined area.

Step 8. Place the flush bolt into the opening, and check to be certain the door prep is deep enough and the bolt does not extend out of the door more than approximately 1/8" less than the minimum clearance. Test the operation of the bolt.

To adjust the height of the bolt, remove the guide from the housing and turn the bolt to raise or lower as necessary. Test the operation of the bolt.

Step 9. With the flush bolt placed into the door, drill the five 9/64" diameter pilot holes to mount the provided #8 Phillips head mounting screws.

Step 10. Install the five screws.

Step 11. Install the faceplate using the provided machine screws.

Step 12. Install the metal rub plate onto the edge of the active door inline with the trigger for each automatic flush bolt. The rub plate is mounted on the active door to protect the wood from the eventual damage caused by the trigger rubbing against the wood.

Step 13. Install the inactive door. With the inactive door closed, test the operation of the automatic flush bolt.

Step 14. Install a door coordinator to ensure that the inactive door closes first, then the active door when both doors are opened.

The use of automatic flush bolts makes it possible for both doors of a double-door entry to be opened without manually releasing the inactive door. At the same time, a cylindrical or mortise lockset can be used to control access.

For more information on the HIT-42FB8 jig, contact your local locksmith wholesaler or Major Manufacturing, Inc., 1825 Via Burton, Anaheim, CA 92806. Telephone: 714-772-5202. Fax: 714-772-2302. Website: www.majormfg.com.

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