Following a slightly less than awesome experience freehand routing mortises for door hinges, I looked for some kind of template / jig that would make the job easier, with better result.

To those who haven't heard the term, a mortise is a recessed area on a door where the thickness of a hinge leaf is set, in order to lie flush with the surface of the door.

We've been slowly replacing all our ugly interior slab doors  with nice looking six-panel beauties. After the initial pocket door experience  and the guest bath door install , I'm getting the hang of it.

Without prior research, (very, very unlike me) I picked up the Ryobi Door Hinge Template at The Home Depot for about $26 bucks last weekend. I don't have much experience with Ryobi products other than to understand that they are regarded as an mid-level, consumer-grade line offered exclusively at Home Depot. Plus, I'm pretty sure Ryobi was a character on some giant-robot Japanese animated series when I was a kid. I thought I'd give it a shot


First off it's plastic. But it's that pretty tough stuff, not brittle. I also liked that all the parts (except drill bit and double end driver bit) fit neatly for on board storage. The kit includes instructions, corner inserts (reversible for 5/8" or 1/4" radius hinges), a guide rail for smaller / laminate routers, a router bit with top pilot-bearing, a 1/8" drill bit, a double-ended driver bit and the hinge mortiser unit itself.



Yep, I'm wearing shorts and sandals. It's 85º today! (Sorry Detroit @ 27º)

It was simple to slip the mortise on the door edge and close the clamp. It's clearly marked to adjust for hinge size. I could see it was right on target because I had already transferred the outline, tracing the hinge itself.


Depth Charge!

I loaded the bit into the old Craftsman router. Depth adjustment is easy. There are marked depth stops for thick or thin hinge plates. You just set the router base on top and crank the bit down until it hits bottom. I had to reset my bit the first time because the collet hit the guide before I had it at full depth. I like this feature, it's the same concept my Porter Cable Dovetail Jig uses to set proper depth.

The instructions are pretty no-nonsense, bullet points. After setting the depth, they simply state:

• Turn on power tool and remove wood from template area 

Well, I guess that about tells the story doesn't it? As Goose would say to Maverick, " Kick the tires and light the fires!"

I took the router for a leisurely drive around the back side of the jig. The bearing rolled along nicely. The bit did it's bit-ing. Looks good. I nearly cut into the front of the jig lifting the router, something to watch in the future. Future Note II - When watching the operation closely, don't forget your dust mask, or at least don't smile too much. The shape of the jig will pretty much wind-tunnel a nice blast of wholesome fiber right at your mouth. <spit>



Flat bottomed: It makes the rockin' world go 'round.

I'm left with a smooth, flat-bottomed mortise. It's lovely. Even with the whole setup, I did it faster than my first free hand cut a couple weeks ago. Feeling that bearing roll along gave me confidence.