Review full instructions prior to use for important safety information.
Always check Rockler.com to confirm that you are using the most recent version of instructions for your product.
Butt Hinge Mortise Template Instructions
Effective Octrober 2022
2BP0222
GENERAL SAFETY WARNINGS
This product is designed only for specific applications as defined in the instructions and should not be modified or used for any
manner not described in these instructions. Use only recommended accessories. Before using the Butt Hinge Mortise Templates:
READ, UNDERSTAND and FOLLOW ALL INSTRUCTIONS AND SAFETY WARNINGS. KEEP THESE INSTRUCTIONS READILY
AVAILABLE FOR FUTURE REFERENCE.
> Always confirm that you are using the most recent version of
the Instructions and safety warnings for your product (see the
Instructions link on the product page at Rockler.com).
> Before using another tool with this product, always read,
understand and follow the instructions and safety warnings
in the owner’s manual for that tool. If you do not have the
owner’s manual, obtain one from the tool’s manufacturer
before using it with this product.
> Before using any chemical with this product, always read,
understand and follow all safety warnings and guidelines in
the manufacturer’s Safety Data Sheet (SDS; formerly called
“MSDS”), especially regarding:
• How to safely use the chemical, including potential hazards
and recommended first aid measures;
• Personal safety equipment required to safely use the
chemical (e.g. gloves, eye protection, mask/respirator, etc.);
• Proper and safe handling, storage and disposal of
the chemical.
> Before using this product, review and verify that all tools to be
used with it have safety equipment installed and are in proper
working order as defined by the tool’s owner’s manual.
> Do not use this product until you have read and are
confident you understand:
• Product Specific Safety Warnings (p. 3);
• Preparing the JIG IT Hinge Mortising System (p. 3);
• Using the Template with the Jig (pp. 3 - 4);
• Hinge Installation Tips (p. 4).
> The user assumes all risk and responsibility for the proper and
safe use of this product and for ensuring product suitability for
the intended application.
> It is the sole responsibility of the purchaser of this product to
ensure that anyone you allow to use this product reads
and complies with all instructions and safety precautions
outlined in this manual prior to use.
> Follow all standard shop safety practices, including:
• Keep children and bystanders away from the tool
operating area;
• Do NOT use power tools in explosive environments, or in
the presence of flammable liquids, fumes or dust;
• TURN OFF AND UNPLUG all power tools BEFORE
making any adjustments or changing accessories;
• Remain alert and use good judgment. Do not use this
product if you are in any way impaired by medications,
alcohol, drugs or fatigue;
• Keep your work area well lit and clean;
• Dress appropriately. Secure loose clothing, remove all
jewelry and tie up long hair before using this product;
• ALWAYS wear safety glasses, hearing protection
and respiratory protection that complies with
NIOSH/OSHA/ANSI safety standards;
• Use dust collection tools and dust face masks to
reduce exposure to dust;
• Use safety equipment such as featherboards, push
sticks and push blocks, etc., when appropriate;
• Maintain proper footing at all times and do not overreach;
• Do NOT force woodworking tools.
> These warnings and instructions do NOT represent the total
of all information available regarding tool safety, use and
technique. Always seek out opportunities to learn more
and improve your skills and knowledge.
Drilling, sawing, sanding or machining wood
products can expose you to wood dust, a substance known
to the State of California to cause cancer. Avoid inhaling
wood dust or use a dust mask or other safeguards for
personal protection. For more information go to
www.P65Warnings.ca.gov/wood.
Danger indicates a hazardous situation that, if not avoided, will result in death or serious injury.
Warning indicates a hazardous situation that, if not avoided, could result in death or serious injury.
Caution indicates a hazardous situation that, if not avoided, may result in minor or moderate injury
or property damage.
Notice indicates important or helpful information and/or user tips.
3
PRODUCT SPECIFIC SAFETY WARNINGS
> To avoid serious injury, keep hands and fingers away from the spinning router bit. Always
maintain awareness of the bit..
> Always make sure that your Butt Hinge Mortise Template
is properly installed in your JIG IT Hinge Mortising
System (58822, sold separately) and that the Hinge
Mortising System is securely clamped to both the lid
and the box before routing. Also make sure that the
assembly will not shift during the routing operation.
> In addition to the warnings provided in these instructions,
the user must comply with all warnings, instructions and
safety guidelines provided by the manufacturer(s) of any
tool or accessories used with this product.
> Turn off and unplug your router before installing the bit or
adjusting the cutter height.
> Always wear safety glasses that comply with OSHA/ANSI
safety standards.
> Wear a dust mask or face covering, use dust collection,
and work in a well-ventilated area.
Preparing the JIG IT Hinge Mortising System
When using the JIG IT Hinge Mortising System with the Butt
Hinge Mortise Templates, it sometimes will be helpful to remove
the clear plastic Fence (identified as Part 2 in the Hinge Mortising
System instructions), depending on how far in from the sides of
the box you will be mounting the hinges. If you are mounting the
hinges somewhat close to the sides, however, the Fence can be
left on and used as a stop for setting up repetitive cuts, and it also
will provide additional clamping surface.
To remove the Fence, remove the Socket-Head Cap Screws and
washers that hold the Fence to the Jig Base and then remove the
Fence. Make sure to store these parts where you will be able to
find them later because you will need them if you use the system
to install quadrant hinges.
Using the Template with the Jig
1. Determine where on the back of the box and lid you want
to install the butt hinges. Clearly mark either the center or
the outer edges of the hinge locations. Accuracy is important,
as you will use these marks to align the template.
> You must have the Rockler JIG IT Hinge Mortising
System (58822, sold separately) to use the Butt Hinge
Mortise Templates. Retrieve the instructions that came
with the jig or download a copy from Rockler.com; you
will need them as a reference.
> Use of this template requires a plunge router,
3/16" diameter straight bit (90000, sold separately) and
a 3/8" O.D. x 5/16"L Guide Bushing Adapter with Lock
Nut (43877 and 63107, each sold separately)
Fence
Front Spacer
Optional Spacer
Check Rockler.com for updates. If you have further questions, please
contact our Technical Support Department at 1-800-260-9663
or support@rockler.com
Make test cuts on scrap to verify the
depth setting on your router. The hinge needs to sit flush or
slightly proud, or the box lid might not close properly.
4Distributed by Rockler Companies, Inc.
4365 Willow Dr. Medina, MN 55340
Rev 10/22
63551 60998 61148 61286 63179
65530 65856 67398 67763 68947
1-800-279-4441
www.rockler.com
2. Choose the correct Butt Hinge Mortise Template for the
hinges you will be using and place it in the opening of the
JIG IT Hinge Mortising System so that the “A” on the
template aligns with the “A” on the jig. Fig. 1.
3. Orient your box and lid as if they’re in the fully open
position and place spacers under the lid so that it is
level with the box.
4. Position the JIG IT Hinge Mortising System on the box and
the lid, with the Front Spacer in between them to ensure that
they’re the correct distance apart. (Depending on how far
in from the end the hinge will be positioned, the Optional
Rear Spacer might also be between box and lid.)
5. Shift the Hinge Mortising System until the etched markings
on the Butt Hinge Mortise Template align with the hinge
location you marked earlier (either centerline or outer
edges). Make sure that the sides of the box and lid are
aligned and ensure that the box and lid are tight against
the underside of the Jig Base. Clamp the lid and box to
the Optional Rear Spacer.
6. Install a 3/16" straight router bit (90000, sold separately) and
a 3/8" O.D. guide bushing and locking nut (43877 and 63107,
sold separately) in a plunge router.
7. Set the bit cutting depth to a hair less than the hinge
thickness. To do this, place the router on the jig with the
bushing in the “A” cutout and — with the router off — slowly
plunge until the bit just makes contact with your box. Engage
the plunge lock. Place a leaf of your hinge under the router’s
depth stop and lower the stop until it contacts the hinge.
8. Double-check that the Template is positioned correctly on
the jig, then make the plunge cut in “A.” Use the bushing
to follow the edges of the cutout, and rout away any material
left in the middle. When finished with the cut, release the
plunge mechanism and allow the bit to stop spinning before
lifting the router from the jig.
9. Test fit a hinge in the mortises you just routed. Fine-tune
the mortises, especially the corners, with a sharp chisel,
if necessary.
10. Repeat the process for any other hinges.
Hinge Installation Tips
To avoid stripping or breaking soft brass hinge-mounting screws,
drill pilot holes and, if possible, tap the holes with a steel screw of
the same size and thread specifications. (Some hinges come with
a steel screw for this purpose.)
If the installed hinge won’t close completely, verify that the
mortise for the lid support (if there is one) is deep enough and
that the hinge is flush or slightly proud of the surface. If you cut
the mortise too deep, small strips of tape or veneer can be used to
shim it up to the proper height.
Fig. 1
“A” letters aligned
/
