TRENhjman
HINGE JIG
Hinge Jig
INTRODUCTION
ITEMS ENCLOSED
1 x Hinge Jig complete
The Trend Hinge Jig is a portable template set
designed for recessing hinges in the door and
the frame. It has been designed for ease of use
and minimal setting up to complete the job both
accurately and quickly. The Hinge Jig has been
tried and tested by contractors with excellent
results.
1 x Spacer
gauge 4mm
■ Use on-site and in joinery shops to increase
productivity.
2 x Bradawl
■ No need for marking out in the conventional
way.
■ Use with soft and hard woods. Tackles knots
with ease.
■ Quick to set up and simple to use.
2 x Nylon
spacer
■ Clean and accurate recesses are achieved
every time.
1 x Template
guide bush
16mm dia. with
10mm long
spigot
■ Suitable for timber based and man-made
doors, door linings and door frames using
square butt hinges.
■ Door linings and door frames.
■ For fire doors.
Specification:
Hinge sizes possible
Length
Min 2 5/8” ___(67mm)
Max 5” ____(127mm)
Width
Min 3/8” ____(9.5mm)
Max 1 3/8” ___(35mm)
1 x Hex key ‘T’
handle 4mm A/F
Door sizes possible
Height
Min 6’ 5” __(1956mm)
Max 7’ __(2100mm)*
Thickness Min 5/8” ____(16mm)
Max 2” _____(51mm)
HINGE
JIG
1 x Manual
IMPORTANT!
GUARANTEE
When unpacking the Hinge Jig,
the cardboard tube and
endcaps should be retained.
Adequate protection can be
gained by returning the hinge
jig to the tube and replacing
the endcap for storage and
transportation.
1 x Guarantee
card
* For doors over 6’ 8” the bottom hinge position can no longer be 9” up from bottom.
-2-
Hinge Jig
SAFETY PRECAUTIONS
■ Do not over-tighten collet as this will score the
shank and create a weakness there.
■ Always switch off the power and unplug the
router when changing cutters or when making
adjustments.
■ It is also advisable to periodically check the
router collet nut for wear.
■ Always wear protective goggles when routing.
Useful Advice
■ Wear sound protective ear muffs when routing
for long periods of time.
■ Do not wear loose clothing. Make sure baggy
sleeves are rolled up and ties are removed.
■ Judge your feed rate by the sound of the
motor. In time, the operator will acquire a
‘feel’ for the router, and a feed speed relative
to the work will come naturally. Too slow a
feed will result in burning.
■ Always remove spanners and hex keys from
the workpiece before switching router on.
■ Apply the normal precautions as with any
electric power tool.
■ Keep hands well clear of the router cutter
when routing.
■ The main abuse of routing machines is the
inclination for operators to overload them.
The motto is ‘Keep the revs up’. The drop in
revolutions should not exceed, if possible,
more than 20% of full running speed.
■ Always wear a dust mask or respirator. Use
dust extraction equipment whenever possible.
■ Avoid accidental starting of the router. Make
sure the power switch is in the ‘Off’ position
before plugging in and connecting to the
electrical supply.
■ The motor of a router is susceptible to the
accumulation of sawdust and wood chips, and
should be blown out, or ‘vacuumed’,
frequently to prevent interference with normal
motor ventilation.
■ Never leave the router unattended when
running. Always wait until the router comes to
a complete stop before making any
adjustments.
■ Refer to the Instruction Manual supplied with
your router for full details of it’s features and
safety information.
■ Do not switch the router on with the cutter
touching the workpiece.
■ Hold the workpiece securely.
■ Trial cuts should be made on waste material
before starting any project.
■ Periodically check all nuts and bolts to make
sure they are tight and secure.
Cutter Care
■ Do not drop cutters or knock them against
hard objects.
■ Cutters should be kept clean. Resin build-up
should be removed at regular intervals with
Resin Cleaner®. The use of a dry lubricant
will act as a preventative such as Trendicote®
PTFE spray.
■ Cutter shanks should be inserted into the
collet at least 3/4 of shank length to prevent
distortion. A distorted collet should be
discarded, as it can cause vibration and
damage the shank.
-3-
Hinge Jig
ASSEMBLY
The jig is already assembled. Please use
drawing below to identify the parts. The only
assembly required is to fit the nylon spacer (13)
onto the bradawl (12). For fire doors the middle
block will need to be moved up to the second
aperture.
6
2
3
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
5
4
7
9
15
4
11.
12.
13.
14.
15.
Jig body
Aperture block
Aperture block retaining screw
Edge stop
Edge stop retaining screw
Swivel end plate and screw
Bradawl hole
End bung
Hinge width scribe line
Template guide bush 16mm with extra long
spigot
Hex key ‘T’ handle 4mm A/F
Bradawl
Nylon spacer
Spacer gauge 4mm
Fire door aperture
3
2
10
1
3
2
9
11
7
5
4
4
2
12
13
3
2
3
14
8
-4-
Hinge Jig
The special guide bush will fit directly onto the
base of routers below. No sub-base is required:
Setting up the Router
Trend
AEG
Atlas Copco
Black & Decker
■ Fit the guide bush to the base of the router
using the screws supplied with the router.
Casals
Champion
Dewalt
Draper
Einhell
Elu
Ferm
Holzher
Kango
Kress
Nutool
Perles
Power Devil
Stayer
Virutex
Wickes
IMPORTANT!
If there is any doubt about the
concentricity of cutters relative
to the guide bush, then a false
sub-base as described below
should be used in order to
ensure an accurate fit of hinges.
For all other makes of router,
the sub-base to suit your router
will need to be purchased.
T3, T5
OF450S, 500S, OFE710
OFS50, 720, OFSE850, 1000
SR100, BD780(E), KW779,
KW780(E), KW800(E)
FT1000
CPR850
DW613, 614, 615
R850V
EOF850SP
MOF96(E), 69
FBF-6E, 8E
2335, 2336, 2356
R8550S
FM6955
NPT850
OF808(E)
PDW5026, 5027
PR50
FR77C, 78C
900W
The UNIBASE is required for the following light
duty routers.
Bosch
Casals
DeWalt
Elu
Festo
Freud
Hitachi
Mafell
Makita
Metabo
Peugeot
Ryobi
Skil
Sparky
■ The UNIBASE Universal Sub-base has a
central recess to allow fitting of the special
guide bush Ref. GB160. The sub-base is
supplied drilled to fit the most popular makes
of routers. See the chart for the correct
selection of sub-base.
■ UNIBASE set contains a circular sub-base,
mounting screws, a line up guide bush Ref.
UNI/GB/6 and centering pins.
■ The 1/4” centering pin and the UNI/GB/6 are
used to align the sub-base with the router
spindle, to ensure concentricity with the guide
bush.
POF400A, 52, 500A, 600ACE
GOF900A, 900ACE,
FT750, 1000(E)
DW620, 621
OF97(E)
OF900(E), 1000(E), 1010EB
FT1000(E)
FM8, ZK2008, M8(V)
L050E
3620
OF528, 1025, OFE1229
DEF570E, DF55E
R150, 151, RE155K, 120
1835U
X52E
The GB/5/S* sub-base is required for the
following routers.
Black & Decker BD60, DN67
Kinzo
25C44
Lynx
RT-800-A
* Please state make and model of router when
ordering.
-5-
Hinge Jig
Fitting the Router Cutter
■ The recommended router cutters for use with
the jig are Refs. 3/8LX1/4TC, C019AX1/4TC
or TR12X1/4TC.
■ The cutters must have a 12.0mm diameter
and a minimum overall length of 66mm.
66mm
■ Unplug router from mains, insert 25mm of
shank of cutter into collet and gently tighten
collet nut.
19mm
12mm
Template Guide Bush principle
■ The cross-section below shows the cutter
being guided by the guide bush around one
of the apertures.
16mm dia.
Guide Bush
Ref. GB 160
Depth stop set to
correct height
12mm dia. Cutter
Ref. 3/8Lx1/4TC
Turret depth stop
Router base
Hinge Jig
Tufnol block
Actual hinge size
Aperture block
required 2mm offset
-6-
Hinge Jig
OPERATION
Setting the Jig for Hinge
Recessing
The jig has three sets of adjustments which
require setting depending on the door size and
thickness, as well as the size and positions of
the hinges. These are all carried out with the
4mm hex key provided with the jig, one hinge
and the 4mm feeler gauge.
The following setting up operation will only need
to be carried out once for a set of doors having
the same height dimensions and hinge sizes.
Setting the Width of the Recess
The width of the recess for the hinge leaf is
governed by the two edge stops. These engage
onto the edge of the door or frame and their
position governs the width of the recess. The
position of each of the two edge stops are set as
follows:■ Undo the edge stop retaining screw with the
hex key.
Jig
2mm scribe
line
Edge stop
■ Place one leaf of the hinge against the edge
stop.
Hinge leaf
position
■ Move edge stop along the slot until leaf edge
of hinge lines up with the inside of the 2mm
scribe line.
■ Tighten edge stop retaining screw with the
hex key.
Setting the Positions of the Recess
The Hinge Jig has been designed to cater for the
traditional positions of the hinges on a door as
follows:
Top hinge -
Located 150 mm (6") from the
top of the door.
Bottom hinge - Located 200 mm (9") from the
bottom of the door.
Centre hinge -
Centrally between the top and
bottom hinges.
-7-
Hinge Jig
Lay the Hinge Jig onto a flat surface e.g. the
edge of the door. The procedure for setting the
position of each hinge is as follows:
■ Slacken block retaining screw of upper
aperture block.
B
Aperture block
■ Measure required position of hinge using tape
measure.
4mm
spacer
gauge
■ Slide block to required position.
4mm offset
■ Tighten block retaining screw.
Hinge
The top aperture has no upper block as it is fixed
at 150mm (6") position from the top of the door.
If only two hinges are used, then only the top
and bottom apertures of the jig will be used.
Aperture
A
Aperture block
securing bolts
Setting the Length of the Recess
The length of the recess for the hinge is
governed by the lower aperture blocks which can
be adjusted for hinges of length 75mm to
105mm. The 4mm spacer gauge is used to give
the necessary offset. The procedure is as
follows for each of the three apertures:-
Jig
■ Place one hinge lengthways into the aperture.
■ Slacken block retaining screw of lower
aperture block.
■ Place spacer gauge between hinge and
upper aperture block.
■ Slide lower block up to hinge.
■ Tighten block retaining screw.
IMPORTANT!
For fire doors, this jig will allow
a second hinge 355mm down
from the top of the upper hinge.
To use with a fire door, move
the middle aperture block up to
the second aperture position
and set to hinge length.
-8-
Hinge Jig
Setting the Depth of the Recess
The depth of the recess must be the same
thickness as the hinge or slightly deeper. Most
routers are fitted with a depth stop to limit the
depth of plunge of the router. Refer to your
router’s instruction manual for particular details
on using the depth stop. The depth of the
recess for the hinge is set as follows:
■ Release depth gauge on the router.
■ Place jig onto the edge of the door.
■ Place router onto jig and locate guide bush
into one of the apertures of the jig.
■ Plunge cutter through aperture until it touches
the edge of the door.
■ Lock the router’s carriage in this position.
■ Move depth gauge up by the thickness of the
hinge by:
1. Either using the depth gauge
measurement/dial
or
2. Placing a leaf of the hinge between the
depth gauge and the stop.
■ Lock off depth stop and remove hinge.
■ Check the depth of the cutter is correct by
first fully plunging the router and locking the
plunge mechanism. Invert the router and
place the jig over the guide bush, now check
that the cutter protrudes past the template the
same distance as the thickness of the hinge.
Double check all settings, ensure all screws are
tight. Setting up is complete.
-9-
Hinge Jig
Routing Hinge Recesses in the
Door
■ The door should be laid on its edge with the
hanging edge of the door facing upwards.
Use the conventional block and wedge to
keep the door securely in this position.
Alternatively clamp the bottom of the door
into the jaws of a Black & Decker®
Workmate®.
■ Place the Hinge Jig onto the edge of the
door. Ensure that the Jig is placed the
correct way round so that the edge stops are
on the knuckle edge of the door. The swivel
end plate should be at the top of the door.
■ Rotate the swivel end plate through 90° and
slide the jig down the door until the swivel
end plate touches the top of the door.
■ Push the jig up to the door so that the edge
stops touch the opening face of the door.
■ Without letting the jig move, locate the
bradawls into the bradawl holes.
■ Hammer the bradawls carefully into the edge
of the door until the nylon spacer fitted to the
bradawls touch the face of the jig.
■ Now plug in the router and place the router
with cutter and guide bush fitted into the first
aperture of the jig.
IMPORTANT!
The swivel end plate fixing
screw may need to be loosened
slightly.
-10-
Hinge Jig
Left hand door
Right hand door
Cutter
Cutter
Door
■ Switch router on and wait for the motor to
reach full running speed. Electronic speed
controlled routers should be set to the
maximum speed.
■ Position the guide bush in the corner of the
aperture and plunge cutter until correct depth
is reached. Lock the carriage of the router in
this position. Rout around the aperture in a
clockwise direction, then remove the waste
from the centre of the aperture. See
drawings opposite for direction of cut to
prevent breakout.
■ Release the carriage of the router and
repeat the procedure for the remaining
apertures.
■ Switch off router and remove jig from door by
pulling out bradawls with a twisting action.
■ Square off rounded corners of hinge recess
with a corner chisel Ref. C/CHISEL and
hammer.
-11-
Hinge Jig
Routing Hinge Recesses in the
Frame
■ No adjustments are necessary to the jig or
the router.
■ Swivel the end plate through 90°.
■ Using the opposite side of the Jig, butt the
top of the jig into the head of the frame and
up against the hanging jamb until the edge
stops touch the opening edge of the frame.
■ Without letting the jig move, locate the
bradawls into the bradawl holes.
■ Hammer the bradawls carefully into the door
frame until the nylon spacer fitted to the
bradawl touches the face of the jig.
■ Now plug in the router and place the router
with cutter and guide bush fitted, into the first
aperture of the jig.
■ Switch router on and wait for the motor to
reach full running speed. Electronic speed
controlled routers should be set to the
maximum speed.
-12-
Hinge Jig
■ Position the guide bush in any corner of
aperture and plunge cutter into frame until
depth, set by depth stop, is reached. Lock
the carriage of the router in this position.
Immediately start routing around the aperture
in a clockwise direction. Then remove the
waste from the centre of the aperture.
Left hand frame
Right hand frame
Cutter
Cutter
Frame
■ Release the carriage of the router and repeat
the procedure for the remaining apertures.
■ Switch off router and remove jig from frame
by pulling out bradawls with a twisting action.
■ Square off rounded corners of hinge recess
with a corner chisel Ref. C/CHISEL and
hammer.
-13-
Hinge Jig
Fitting the Door
■ Fit hinges to door and raise upright.
■ Use a jack to raise door until hinges align
with recess.
■ Screw leafs to frame.
Providing procedure is carried out correctly and
that the frame/lining is plumb and parallel, then
no adjustment should be necessary due to the
identical mirror image positioning of the recesses
in both the door and the frame.
Other Points
If a larger gap is required to accommodate
smokeseal or draft excluder, a packing piece can
be temporarily glued or stuck to the swivel end
plate in order to utilise the jig in the same
technique and achieve accurate results.
If a new door is being hung in an existing frame
or lining, the door height may be shortened by a
timber threshold or parquet flooring or by a new
screed. This may cause problems with the jig
fitting the door.
Finishing the Frames
The holes left by the bradawls are on both
closing edges of the door and frame and are
very unobtrusive. These can be easily filled with
a matching coloured filler.
IMPORTANT!
Release the plunge action on
the router after each hinge, as
not doing so could result in
cutting into the edge of the jig
and causing damage. If you
damage the jig or blocks, an
epoxy resin (e.g. Araldite®
Epoxide Resin) can be used to
fill the gap and if rubbed
smooth will provide a
continuous edge on which the
guide bush can follow.
Guarantee
■ The jig carries a manufacturers guarantee in
accordance with the conditions on the
enclosed guarantee card.
Recycling
■ Jig, accessories and packaging should be
sorted for environmentally friendly recycling.
-14-
14 6
HINGE JIG
SPARE PARTS DIAGRAM
5
13
3
2
15
12
9
10
17
16
2
4
8
12
HINGE JIG - SPARE PARTS LIST
-15-
18
1
Hinge Jig
Ref.
WP-HJ/01
WP-HJ/02
WP-HJ/03
WP-HJ/04
WP-HJ/05
WP-HJ/06
WP-HJ/07
WP-HJ/08
WP-HJ/09
WP-HJ/10
WP-HJ/11
WP-SCW/51
WP-SCW/52
WP-SCW/56
WP-PIN/01
WP-AKT/01
GB160
MANU/HJ
2
11
2
2
4
12
12
7
v4.0 11/2001
Description
Aluminium Template
Aperture Block
Upper Edge Stop
Lower Edge Stop
End Block
Swivel End Plate
End Bung
Nylon Spacer
Bradawl
Feeler Gauge 4mm
Hinge Jig Label
Machine Screw Csk M6 x 16mm Skt
Machine Screw Csk M6 x 40/18mm Skt
Machine Screw Small Csk M6 x 12mm Skt
Split Pin 3mm x 25mm
Hex Key ‘T’ Handle 4mm
Guide Bush 16mm Dia. x 10mm Spigot
Manual
JIG
3
v4.0 11/2001
12
Item Qty
1
1
2
5
3
2
4
2
5
1
6
1
7
1
8
2
9
2
10
1
11
1
12
5
13
2
14
1
15
2
16
1
17
1
18
1
HINGE
13
Hinge Jig
Quick Start Instructions
Routing the Frame
These instructions are provided for those who
are confident with the router and are already
familiar with the Hinge Jig.
1. Rotate the end plate until flush with jig.
Setting Up
3. Ensure edge-stops touch edge of frame.
1. Fit router cutter & guide bush to router.
4. Secure jig to door frame using the two
bradawls.
2. Position door with hanging edge
uppermost.
3. Adjust two edge stops to width of hinge.
4. Place hinge jig on hanging edge of door.
5. Rotate the end plate at 90° to jig.
6. Ensure end plate touches end of door.
2. Butt the end plate into the head of frame.
5. Locate guide bush into aperture and switch
router on.
6. Plunge down router and rout clockwise.
7. Repeat routing operation for each hinge
recess.
8. Chisel corners square by hand to receive
hinges.
7. Ensure edge-stops touch opening face
of door.
8. Secure jig to door using the two
bradawls.
9. Adjust top blocks to position of hinges.
10. Adjust bottom blocks to length of hinges.
11. Adjust depth stop on router to thickness of
hinge.
12. Switch router on & locate guide bush into
aperture.
13. Plunge down router and rout clockwise.
14. Repeat routing operation for each hinge
recess.
15. Chisel corners square by hand to receive
hinges.
-16-
MANU/HJ v4.0
RECYCLABLE
Trend Machinery & Cutting Tools Ltd.
Odhams Trading Estate St Albans Road
Watford WD24 7TR England
Enquiries: __________________0800 487363
Technical Support: ___ 0044 (0) 1923 224681
Fax: ________________0044 (0) 1923 236879
Email:[email protected]
WWW: _________________www.trendm.co.uk
© Copyright Trend 2001. No part of this publication may be reproduced, stored or transmitted in any form without prior permission. Our
policy of continuous improvement means that specifications may change without notice. Trend Machinery and Cutting Tools cannot be
held liable for any material rendered unusable or any form of consequential loss. E&OE
® All registered trademarks acknowledged.
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