Door Hinge Duplicator
thingiverse
I've been busy replacing numerous internal 1 3/8" doors within my home. Making precise cuts for the hinges is a fascinating task, so I designed a jig to utilize the old door as a template. Position the doors on top of each other and align them perfectly. Secure the doors together firmly using clamps to prevent any movement. (Achieving proper alignment is essential!) Attach the jig to the old door hinge cutout by inserting 1 1/4" flat head screws into the existing hinge screw holes. Next, use a router equipped with a standard 5/8" router guide bushing and a 1/2" router bit. I set the router's depth to make a precise 3/64" cut, which has proven highly effective for me.
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