Door hinge mortise jig

thingiverse

Cutting a precise mortise into a door or jamb for a 3 1/2" hinge with 5/8" corners requires a specialized jig when using an offset router bit. I recently created a custom jig to tackle this task, and I'm excited to share my experience. The offset router bit I used is available on Amazon here: https://smile.amazon.com/dp/B06WVDHM14 - it features a 1/2" diameter cutter and a bearing of 5/8". To ensure the jig withstands the rigors of cutting, I added a 1/16" offset to the edges. This thoughtful design detail prevents the jig from getting damaged during use. My trusty trim router is an older model of this reliable Harbor Freight tool: https://www.harborfreight.com/power-tools/routers-cutout-tools-lathes/14-in-24-amp-trim-router-62659.html. The 1/8" holes used to secure the jig in place were easily filled with M3x16 wood screws I had on hand. By keeping the jig long, I found it easier to achieve a straight cut. Not having alignment tabs allows for adjustments as needed and makes the jig usable on both doors and jambs. The Fusion360 source code is included below.