Synopsis: Becoming hinges is without doubt one of the largest demanding situations for new boxmakers. This jig is helping Doug Stowe’s scholars get completely matching hinge mortises on each the field and its lid. This jig merely clamps to the field frame and the bench, and slides to the opposite finish for the second one mortise. Recommendations on the use of the jig and adapting it to other tasks are integrated.

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I’ve made a large number of boxes and taught a large number of other folks the way to lead them to. One of the most spaces that scholars to find maximum difficult is becoming hinges to a just about completed field. To lend a hand my scholars throughout all categories and boxes, I devised a quick-and-easy jig with notches for the router to practice and a fence to place it in opposition to the workpiece. The jig all however promises completely matching mortises within the field and its lid. Fortunately, it really works simply as smartly for me in my very own store.

Finish stops are the important thing to clean registration With notches sized to a particular hinge and a fence and forestalls for certain reference, this no-frills jig takes the headache out of becoming hinges to a field and its lid—or many boxes and plenty of lids. The top stops lend a hand make sure that correct alignment between the field and lid.

 

Symmetrical jig with stops

Tailor your jig on your router, hinges, and boxes. The jig’s base will have to be 1 in. or extra longer than the longest field you are expecting to make with a specific hinge and vast sufficient to with ease strengthen your router. I discover a trim router to be superb right here, because it’s small, light-weight, and clean to regulate. I take advantage of a three ⁄ 16-in.-long dado blank out bit from MLCS (merchandise no. 5382).

Since the notches within the jig are sized to a particular hinge, you wish to have to make a separate jig for each and every measurement of hinge you’ll use. Fortunately, making one is a work of cake.

To put the notches, make a decision how a ways you wish to have each and every hinge from the tip of the field. Typically 1 in. or so works smartly for the vast majority of small and medium boxes I make. That distance assists in keeping the hinge screws safely clear of the corners so that they don’t compromise the joints.

On the tablesaw, I reduce the notches to the precise width of the hinge. Arrange two stops on a sled to restrict the side-to-side go back and forth of the jig base. After each and every reduce, attempt to are compatible the hinge within the notch. Preferably, the primary reduce can be too tight, letting you faucet a prevent away as you creep up on a cosy are compatible.

Surroundings the blade top calls for some math, now not take a look at becoming. It must be raised sufficient to account for the hinge mortise plus the width of the fence. I want about part of the hinge barrel to stay out in the back of the field, offering a complete vary of movement. So that you could decide the intensity of the sawcut, measure from the brink of the hinge leaf to the barrel and upload 1⁄2 in. for the width of the fence.

After homing in at the notch at one finish, turn the bottom finish for finish and reduce the second. As a result of I turn the bottom to chop the second one notch, each notches can be similarly spaced from the tip of the jig, simplifying the jig’s use.

To complete the jig, glue at the fence and finish stops, being cautious that the strips are flush with the fringe of the bottom.

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Make the jig

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Jig’s a template that slides and flips

To rout the mortises, I take advantage of the dado blank out trend bit discussed previous. Its brief reducing duration method there’s a lot of room left for the bearing to sign up at the jig’s notches.

To make use of the jig, clamp it and the field frame to the bench, ensuring the field is tight to the jig’s finish prevent and fence, and rout. If you wish to have to sq. the corners of the mortise, depart the jig clamped in position, since it’s going to lend a hand information your chisel paintings. To rout the opposite mortise, merely slide the jig to the opposite finish of the field and undergo the similar technique of routing and slicing.

For the lid, turn the jig and repeat. You’ll finally end up with matching mortises with little format or fuss.

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Mortise the field

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A tip for environment the bit intensity

Surroundings the bit’s intensity generally is a problem, so I like to recommend a take a look at run.

I decrease the bit in order that it extends 1 ⁄ 2 in. (the bottom’s thickness) plus part the thickness of the hinge barrel. I then decrease it any other hair to stay the hinges from binding.

Seize a work of scrap and rout two take a look at mortises. By way of then crosscutting the scrap in two, you’ll put the mortises in combination to simulate the routed field and lid.

Put the hinge barrel on this area. If the hinge falls out, the reduce is simply too deep. As an alternative, you wish to have the take a look at blocks to pinch the barrel in position with an opening of about 1 ⁄ 64 in. between the blocks. Then your hinges will function easily and the relationship between the field and lid will glance blank.

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Mortise the lid

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—Doug Stowe is an writer and boxmaker in Eureka Springs, Ark.

Pictures: Barry NM Dima.

Drawings: Dan Thornton.

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From Fantastic Woodworking #301

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