ROCKLER GRP41444 Butt Hinge Mortise Template Instructions

: June 3, 2024
: ROCKLER

Table of Contents

ROCKLER GRP41444 Butt Hinge Mortise Template
GENERAL SAFETY WARNINGS
PRODUCT SPECIFIC SAFETY WARNINGS
Hinge Installation Tips
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

ROCKLER GRP41444 Butt Hinge Mortise Template

GENERAL SAFETY WARNINGS

This product is designed only for specific applications as defined in the instructions and should not be modified or used for any manner not described in these instructions. Use only recommended accessories. Before using the Butt Hinge Mortise Templates: READ, UNDERSTAND and FOLLOW ALL INSTRUCTIONS AND SAFETY WARNINGS. KEEP THESE INSTRUCTIONS READILY AVAILABLE FOR FUTURE REFERENCE.

Always confirm that you are using the most recent version of the Instructions and safety warnings for your product (see the Instructions link on the product page at Rockler.com).
Before using another tool with this product, always read, understand and follow the instructions and safety warnings
in the owner’s manual for that tool. If you do not have the owner’s manual, obtain one from the tool’s manufacturer before using it with this product.
Before using any chemical with this product, always read, understand and follow all safety warnings and guidelines in the manufacturer’s Safety Data Sheet (SDS; formerly called “MSDS”), especially regarding:
- How to safely use the chemical, including potential hazards and recommended first aid measures;
- Personal safety equipment required to safely use the chemical (e.g. gloves, eye protection, mask/respirator, etc.);
- Proper and safe handling, storage and disposal of the chemical.
Before using this product, review and verify that all tools to be used with it have safety equipment installed and are in proper working order as defined by the tool’s owner’s manual.
Do not use this product until you have read and are confident you understand:
- Product Specific Safety Warnings (p. 3);
- Preparing the JIG IT Hinge Mortising System (p. 3);
- Using the Template with the Jig (pp. 3 – 4);
- Hinge Installation Tips (p. 4).
The user assumes all risk and responsibility for the proper and safe use of this product and for ensuring product suitability for the intended application.
It is the sole responsibility of the purchaser of this product to ensure that anyone you allow to use this product reads and complies with all instructions and safety precautions outlined in this manual prior to use.
Follow all standard shop safety practices, including:
- Keep children and bystanders away from the tool operating area;
- Do NOT use power tools in explosive environments, or in the presence of flammable liquids, fumes or dust;
- TURN OFF AND UNPLUG all power tools BEFORE making any adjustments or changing accessories;
- Remain alert and use good judgment. Do not use this product if you are in any way impaired by medications, alcohol, drugs or fatigue;
- Keep your work area well lit and clean;
- Dress appropriately. Secure loose clothing, remove all jewelry and tie up long hair before using this product;
- ALWAYS wear safety glasses, hearing protection and respiratory protection that complies with NIOSH/OSHA/ANSI safety standards;
- Use dust collection tools and dust face masks to reduce exposure to dust;
- Use safety equipment such as weatherboards, push sticks and push blocks, etc., when appropriate;
- Maintain proper footing at all times and do not overreach;
- Do NOT force woodworking tools.
These warnings and instructions do NOT represent the total of all information available regarding tool safety, use and technique. Always seek out opportunities to learn more and improve your skills and knowledge.

WARNING: Drilling, sawing, sanding or machining wood products can expose you to wood dust, a substance known to the State of California to cause cancer. Avoid inhaling wood dust or use a dust mask or other safeguards for personal protection. For more information go to
www.P65Warnings.ca.gov/wood.

DANGER: Danger indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING: Warning indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION: Caution indicates a hazardous situation that, if not avoided, may result in minor or moderate injury or property damage.
NOTUCE: Notice indicates important or helpful information and/or user tips.

PRODUCT SPECIFIC SAFETY WARNINGS

DANGER:
To avoid serious injury, keep hands and fingers away from the spinning router bit. Always maintain awareness of the bit..

ROCKLER-GRP41444-Butt-Hinge-Mortise-Template-02 WARNING:

Always make sure that your Butt Hinge Mortise Template is properly installed in your JIG IT Hinge Mortising System (58822, sold separately) and that the Hinge Mortising System is securely clamped to both the lid and the box before routing. Also make sure that the assembly will not shift during the routing operation.
In addition to the warnings provided in these instructions, the user must comply with all warnings, instructions and safety guidelines provided by the manufacturer(s) of any tool or accessories used with this product.
Turn off and unplug your router before installing the bit or adjusting the cutter height.
Always wear safety glasses that comply with OSHA/ANSI safety standards.
Wear a dust mask or face covering, use dust collection, and work in a well-ventilated area.

ROCKLER-GRP41444-Butt-Hinge-Mortise-Template-02 NOTUCE

You must have the Rockler JIG IT Hinge Mortising System (58822, sold separately) to use the Butt Hinge Mortise Templates. Retrieve the instructions that came with the jig or download a copy from Rockler.com; you will need them as a reference.
Use of this template requires a plunge router,
3/16″ diameter straight bit (90000, sold separately) and a 3/8″ O.D. x 5/16″L Guide Bushing Adapter with Lock Nut (43877 and 63107, each sold separately)

Preparing the JIG IT Hinge Mortising System
When using the JIG IT Hinge Mortising System with the Butt Hinge Mortise Templates, it sometimes will be helpful to remove the clear plastic Fence (identified as Part 2 in the Hinge Mortising System instructions), depending on how far in from the sides of the box you will be mounting the hinges. If you are mounting the hinges somewhat close to the sides, however, the Fence can be left on and used as a stop for setting up repetitive cuts, and it also will provide additional clamping surface.
To remove the Fence, remove the Socket-Head Cap Screws and washers that hold the Fence to the Jig Base and then remove the Fence. Make sure to store these parts where you will be able to find them later because you will need them if you use the system to install quadrant hinges.

Using the Template with the Jig

Determine where on the back of the box and lid you want to install the butt hinges. Clearly mark either the center or the outer edges of the hinge locations. Accuracy is important, as you will use these marks to align the template.
Choose the correct Butt Hinge Mortise Template for the hinges you will be using and place it in the opening of the JIG IT Hinge Mortising System so that the “A” on the template aligns with the “A” on the jig. Fig. 1.
Orient your box and lid as if they’re in the fully open position and place spacers under the lid so that it is level with the box.
Position the JIG IT Hinge Mortising System on the box and the lid, with the Front Spacer in between them to ensure that they’re the correct distance apart. (Depending on how far in from the end the hinge will be positioned, the Optional Rear Spacer might also be between box and lid.)
Shift the Hinge Mortising System until the etched markings on the Butt Hinge Mortise Template align with the hinge location you marked earlier (either centerline or outer edges). Make sure that the sides of the box and lid are aligned and ensure that the box and lid are tight against
the underside of the Jig Base. Clamp the lid and box to the Optional Rear Spacer.
Install a 3/16″ straight router bit (90000, sold separately) and a 3/8″ O.D. guide bushing and locking nut (43877 and 63107, sold separately) in a plunge router.
NOTICE:|
Make test cuts on scrap to verify the depth setting on your router. The hinge needs to sit flush or slightly proud, or the box lid might not close properly.
Set the bit cutting depth to a hair less than the hinge thickness. To do this, place the router on the jig with the bushing in the “A” cutout and — with the router off — slowly plunge until the bit just makes contact with your box. Engage the plunge lock. Place a leaf of your hinge under the router’s depth stop and lower the stop until it contacts the hinge.
Double-check that the Template is positioned correctly on the jig, then make the plunge cut in “A.” Use the bushing to follow the edges of the cutout, and rout away any material left in the middle. When finished with the cut, release the plunge mechanism and allow the bit to stop spinning before lifting the router from the jig.
Test fit a hinge in the mortises you just routed. Fine-tune the mortises, especially the corners, with a sharp chisel, if necessary.
Repeat the process for any other hinges.

Hinge Installation Tips

To avoid stripping or breaking soft brass hinge-mounting screws, drill pilot holes and, if possible, tap the holes with a steel screw of the same size and thread specifications. (Some hinges come with a steel screw for this purpose.)
If the installed hinge won’t close completely, verify that the mortise for the lid support (if there is one) is deep enough and that the hinge is flush or slightly proud of the surface. If you cut the mortise too deep, small strips of tape or veneer can be used to shim it up to the proper height.
Check Rockler.com for updates. If you have further questions, please contact our Technical Support Department at 1-800-260-9663
or support@rockler.com