Can I use a router for door hinges?

Using a router for door hinges may seem like an unusual idea at first glance. However, with some creative thinking and the right router bits, it is possible to use a router to create hinges for doors. There are a few key considerations when determining if a router can work for your door hinge project.

The basics of using a router for hinges

A router is a versatile power tool typically used for cutting grooves and decorative edges into wood. With the right router bit, you can use a router to cut hinge mortises – the recessed areas that allow a hinge to sit flush in the door. Here are the basics steps for using a router to create door hinges:

1. Purchase or make hinge templates – These are guides that will allow you to position and cut the hinge mortises in the exact right dimensions for the hinges you plan to use.
2. Attach hinge template to door and jamb – The templates get clamped or screwed in the exact positions where you want the hinges placed.
3. Set router bit depth – Adjust so it cuts deep enough for the hinge hardware to sit flush.
4. Cut hinge mortises with router by tracing template edges – Use the template outlines as a guide for the router to follow.
5. Test fit hinge hardware – Make sure the sizing is accurate by test fitting the hinges in the mortises.
6. Make any adjustments needed for good fit.

With the right templates and setup, a router can cut nice clean mortises for hinges. The edges will have a uniform shape and depth. This can result in an integrated, seamless look compared to just screwing hinges directly to the surface.

Benefits of using a router

Here are some of the advantages of using a router compared to other methods when installing door hinges:

• Accuracy – The router can closely follow a template so hinge mortises are positioned precisely where needed.
• Consistency – Each hinge mortise will have the exact same dimensions when using a template.
• Smooth edge – A router cuts a clean edge shape into the mortise opening.
• Depth control – It’s easy to set the specific depth needed for a flush hinge fit.
• Faster than chisel – A router mortising setup is quicker than cutting each hinge recess by hand.

These advantages make a strong case for using a router rather than just attaching hinges directly to the door surface. The mortises result in neater, more integrated hinges.

Potential challenges

While using a router for hinges has its benefits, there are also some potential challenges to consider:

• Learning curve – There are techniques and adjustments needed to master routing good mortises.
• Dust – Routing can make a mess from wood particles – protect nearby surfaces.
• Template making – You’ll need precise hinge templates unless you can purchase them.
• Size limitations – A router may not work as well for extremely large hinges.
• Hinge alignment – Any template imperfections can throw off hinge placement.

None of these are dealbreakers. However, there is a bit more involved compared to just drilling pilot holes and screwing hinges in place. Take precautions for dust, allow time to practice, and double check measurements.

Router and bit selection

Nearly any standard fixed-base or plunge router will work for hinge mortising. Variable speed is helpful to adjust from slower template guiding to faster mortise cutting. Here are some good router choices:

Router	Details
Bosch 1617EVSPK	Popular mid-size fixed/plunge kit
DeWalt DW618PK	Powerful mid-size plunge and fixed combo
Porter Cable 892	Legendary workhorse plunge router

A straight cutting bit is needed to create the clean rectangular mortise for the hinge. 1/2″ shank bits with a bearing guide are recommended. Good options include:

• Whiteside 5100
• Freud 99-275
• Amana 45300

The exact width needed will depend on your hinge size. Test on scrap first to check your setup before moving to the actual door and jamb.

Hinge jig options

A hinge jig or template is crucial for accurate, easy routing. Here are two options to consider:

Shop-made hinge routing jig

You can make your own MDF or plywood routing jig, using your hinges to outline the exact mortise positions and size. Add handles and registration keys for easy aligning on your door and jamb. This takes some work, but allows complete customization for your hinges.

Hinge mortise kit

Aftermarket jig kits are available that include both door and jamb templates. Registered positioning keys help quickly align the templates. This makes the process much easier, though you’ll need a kit that fits your hinge size. Options from Rockler or Milescraft are good quality.

Steps for routing hinges

Once you have your router, bit, and jig ready, here is the process for routing hinge mortises:

1. Set router bit depth – Adjust so it cuts deep enough for hinges to be flush.
2. Clamp jig template to door – Register against door edge for proper alignment.
3. Route door mortises – Carefully follow template edges with router base.
4. Clamp jig to jamb – Register and realign to match door mortises.
5. Route jamb mortises – Again trace template perimeter with router.
6. Test fit hinge in mortises – Adjust as needed for good fit.
7. Finish routing all hinge mortises on door and jamb.
8. Install hinges and enjoy your seamless fit!

Take light passes when routing out the mortise area. Move router left to right and right to left across the opening to clear out the middle. Go slowly when initially tracing the template edges.

Tips for clean hinge routing

Follow these tips for getting the highest quality results from your hinge routing:

• Use sharp router bit – Dull bits require more force and tearout issues.
• Work in multiple passes – Don’t try to rout full depth in one pass.
• Use backer board under jamb – Reduces potential blowout when routing.
• Adjust settings on test piece – Dial in speed, depth, etc. on scrap first.
• Secure workpieces firmly – No movement or vibration for clean cuts.
• Go slow – Don’t rush the template tracing passes.
• Clear chips frequently – Prevent buildup in mortise.

Patience and practice will pay off with tightly fit hinges recessed snugly into mortises. The results are worth the extra effort compared to surface-mounting the hinges.

Alternative hinge mortising options

While a router is an excellent tool for cutting hinge mortises, there are a couple other options that may work well depending on your specific needs:

Mortising machine

A dedicated mortising machine with a square chisel bit can make quick work of hinge mortise cutting. This is best for high volume production work. Machines from Powermatic or Baileigh are excellent for mortising.

Chisels and mallet

For just a few hinges, chisels and a mallet may be the simplest approach. Lay out mortise locations precisely, then pare away the waste wood gradually with sharp chisels. It takes practice, but the tools are inexpensive.

Consider how many hinges you need to install and your available tools and budget when deciding on the best mortising method. For most DIYers and woodworking hobbyists, a router offers a good balance of productivity and setup ease.

Finishing touches

Once your hinges are installed in their routered mortises, add some finishing touches for a seamless professional look:

• File edges smooth – Remove any splinters or fuzziness from routing.
• Sand mortises – Light sanding blends edges smoothly.
• Fill gaps if needed – Use thin wood shims and glue if any small gaps are visible.
• Stain or paint to match – Blend mortise edges to match surrounding surface.
• Seal hinge hardware – Use thin CA glue or epoxy to prevent loosening over time.

Taking these extra steps results in hinges that look like they are integrated directly into the door and jamb. Passersby won’t even notice them at a glance. The clean mechanical look is an impressive touch for furniture builds or any wood project needing hinges.

Conclusion

While it may sound unorthodox at first, using a router is an excellent method for installing door hinges. The router cuts clean, accurate mortises with a uniform shape and depth. Hinges sit flush within these mortises for a seamless integrated appearance. With the proper template setup and jig, a router can quickly cut hinge mortises that would be difficult to produce by hand.

There are some challenges to the technique including dust, learning curve, and potential tearout. But with sharp bits, reasonable feed rates, and scrap practice runs, you can achieve great results. The mortise appearance is far more attractive than just screwing hinges directly to the surface. For woodworkers looking to step up their hinge game, routing mortises is worth considering.

So don’t dismiss the idea of using a router for door hinges. With care and the right jig setup, your router can help install hinges that look like they belong right where they are. The clean mechanical integration of mortise and hinge will impress onlookers. It’s an advanced touch that relies on a standard woodworking tool in an unconventional way.