Going to be making up door linings, so need to provide trench cut, Chop saw doesn't have trench facility. Made the jig to route of lining upto 150mm wide. Using a 16mm guide bush with 1/2" cutter. Jig is secured in place using screws, they are sunk below the surface, which have been positioned so they will be covered up by door stops. The batten is referenced up to edge of lining before fixing. Made cutout by using chop saw to plunge saw blade in to provide cuts on either side, before finishing off with handsaw. Now trimmed to size. A length of batten was secured with screws, making sure it its right angle to cut. This is a scrap piece of blockwood which shows the finished piece, board is wider than 145mm. Need to do a few hosuing joins so made this jig, took about 1/2 to makeusing 12mm thick plywood.
Its going to save my quite a bit of time. The batten underneath has been routed slightly, which wasn't planned but provided a reference line. Just need to line up this edge to the finished cut. May even may a hinge jig now....
I meant there are easier and quicker ways of making the jig but I'm sure you will get better ideas as you progress. I love making jigs.
Going to buy a router cutter with top bearing to cut flush. Was going to make an offset jig, but will make the jig to the exact size then using the flush trim bit to cut the hinge recess. While I have jig in place and clamped up, it can be used as a guide to clean out the waste with chisel. Watched a few videos, where the cut out the jig to rough size then stick timer to the jig using double sided tape.
For your Dewalt router just fix two battens the width of the router base to run at 90 degrees either side of where the cut out is. The square shoulders of the base will then run along them. This way you don't need to use the guide bush
Template cutter arrived this morning, been waiting all week for it. Wood going to be used as a test piece. Hinge jig is fixed, not adjustable. Made using 18mm plywood. Hinge was cut out exactly to size. Wood had been routered. While in place the jig can be used to help guide chisel to remove corers where bearing hasn't reached. Finished cut. Hinge fits in very snuggly with minimal play. Trend cutter I used, most were too long which mean bearing couldn't be used. cost £16 Going to save me a lot of time especially as ill be fitting oak doors. Should be able to rout out recess in lining before architrave have been fitted.
Trend do several Long reach cutters for Hinge Jigs. http://www.screwfix.com/p/trend-lon...x-19mm/90479?dclid=CPDH9K-H79ICFaui7Qodw5gB7w
With the bearing hinges, check them after about a month or so as the grease can ooze out with the weight of the door.
I have 7-8 doors with pair and half hinges per door so 24 in total. Only taken me about 1 hour to make. Normally takes me 20 minutes to cut each recess by hand. Could have use trimmer to cut out main waste, but need to be careful to cut within line.