Replies

1. 
   mike4244 | Nov 07, 2002 09:49pm | #1

   I have used the Porter Cable but not the others. The PC will do the jambs without removing door stop.The spring loaded pins are similar to cork board tacks, they leave a small hole.If you are not going to use these jigs often you can make your own.

   I use 3x3 aluminum angle for the door. This could be used for the jamb if the trim is not installed.The cutout in the angle for the mortise has to be the size of the hinge plus distance from edge of cutter with bushing attached. On my PC router with bushings, the size of 4" hinge cut out on the jig is 4 3/8". This allows 3/16 on each side.The width of a 1 3/4" leaf is 3/16" more or 1- 15/16" . 

   The bushing may have to be cut for length or the angle blocked up 1/2".This depends on the bushings you would use.If this is too much trouble the Hingemate looks like a good alternative. I have never used the Hingemate but people I know like them.

2. 
   RW | Nov 08, 2002 01:48am | #2

   Used the PC but only for about a thousand doors, so not a lot of experience with it. *grin* The spring loaded pins do leave small holes. On our setup these were inconsequential. They aren't big nasty gouges. No idea on with or without a stop (though from above looks like it can). Works well and quickly. We always just hung the hinge side first and anchored it, routed it on the wall, routed the door, hung it, then worked around - head - latch side - stops - casing. If you're going to use a router and a collet get a little block of ply and cut a rectangle in it (you'll have to play for accuracy) and size it so your router cuts your recesses for the strike plates too. Maybe that doesn't matter if you're only doing one. For a lot, it's an easy little jig and handy to keep around.

1. 
   WW_wannabe | Nov 08, 2002 03:46am | #3

   Thanks, This is a great help.

   Imran

1. 
   Sancho | Nov 08, 2002 05:38am | #4

   have you look at templaco templates.

   At Darkworks cut to size made to burn......Putty isnt a option

1. 
   PlaneWood | Nov 08, 2002 07:21am | #5

   I just gave my old one to a guy down the street.  Was a Sears model that my dad bought 40 years ago.   I think in the last 30 years I maybe used it to hang 10 doors.  Sure a great way to get all the mortises to match!  With it, the jamb strip had to be removed.

   PlaneWood by Mike_in_KatyPlaneWood

2. 
   WW_wannabe | Nov 08, 2002 02:38pm | #8

   Ron,

   No I have not. Where can I find info on it.

   Imran

1. 
   Sancho | Nov 08, 2002 06:56pm | #9

   Well most tool stores and Ive seen them at the home depot but not in the best condition a full line, Ganahl Lumber has a good supply of them here in SoCal, various sizes 3", 3 1/2", 4" ect as well as templates for mortising the lock plates in various sizes. They have a website, im not exactly sure of the address but you could try http://www.templaco.com like i said Im not sure if that is it .

   At Darkworks cut to size made to burn......Putty isnt a option

2. 
   WW_wannabe | Nov 09, 2002 02:48pm | #12

   Thanks, Ron. Tried the website. Definetaly an option when one does not need to transfer hinge location from jamb to door. Seems like it would be fastest template to use.

   Imran

3. 
   Sancho | Nov 09, 2002 06:50pm | #14

   They sell the individual single templates i pay about 20 bucks ea for them in the various sizes. What i do is line the old door to the new one and transfer the hinge locations then use the single template to route out the mortises on the door. just be sure to mark one side of the old door when doing this cuz when its off the hinges it can get a tad confusing and you'll end up (as I did) and router out the wrong side. But other then that is fairly simple.

   At Darkworks cut to size made to burn......Putty isnt a option

3. 
   JPGrout | Nov 08, 2002 08:34am | #6

   I use both the PC and the Bosch jig you mentioned and find them to be very accurate. A quick overview here. the Porter Cable pockets are adjusted by moving two plates in each of the fixtures, in essence you are always working from the center of the pocket with the PC. The Bosch has a movable pin and a row of holes that represent the size of the hinge on the opposite end is a movable plate that allows fine adjustment of the pocket.The height of the jig is also adjustable for different sized hinges and door heights to 7' They both use small pins to attach the jig to the work and I have found that it takes nothing to fill the holes if desired after you finish. The height adjustments are basically the same you adjust for the door height by extending or contracting the beams. I have a preference for the Bosch jig but only because I use it more. They both have their little issues, but either one will work just fine. I also build my own custom jigs for different spacing or door heights Or just use a single jig to lay out when more than three hinge are required. There a accessory kits available for both jig to expand to four pockets for 8' doors as well but they are expensive. The one thing I should warn you of is not to hit the guide rails with a spinning router bit. It is possible to repair the damage (I use bondo body putty) but it does put a crimp in your day. As was stated in another post, I too have used these jigs extensively as we probably assemble at least 100 doors a month with these jigs. A door machine requires about that many a day to turn a profit and the ones I have seen are not very efficient with custom sizes and hardwood doors. Joe

1. 
   WW_wannabe | Nov 08, 2002 02:36pm | #7

   Thanks for the detailed response. I most likely will pick up Bosch just because it looks a little more substantial (beefy) in the picture.

   Imran

1. 
   clampman2 | Nov 09, 2002 07:34am | #10

   Imran,

   I have only used the PC a couple times, but far prefer my old Stanley which looks nearly identical to the Bosch. For one thing, the Bosh fits neatly into a small box, making it easier to throw into larger boxes (like job boxes), behind the seat of a pickup etc etc. The edge rails and ends of mine, I repaired by brazing with coathangers after occasional inexplicable incidences of router bite syndrome. And I had to turn new pins recently because the old ones could no longer be rotated in a way to avoid the pin chatter rash disease that mine had slowly been coming down with over the years.While I was at it, I made a new spring loaded stick pin to replace the one that went looking for a new home. I almost lost the other one I had to remove so I could switch it back and forth every time I switched from door to jamb.

   I switched out all the original screws for socket head cap screws (allen head machine screws) for ease of adjustment and finer touch in torqueing. (Is that a word? It don't look right). And also because a few of the originals disolved or something.

   Except for its poor immune system to the diseases mentioned above, I think it is the best built and designed one I have seen. But then I am very gentle and easy on my tools.

   Clampman

1. 
   WW_wannabe | Nov 09, 2002 02:45pm | #11

   I enjoyed reading your response. I also had another response about Stanley being really good and that it is sold as Bosch now. I have checked the Templaco website (above response) and that is a very good source as well.

   Thanks,

   Imran

2. 
   JPGrout | Nov 09, 2002 05:45pm | #13

   FYI parts for the Bosch/ Stanley jigs are interchangable. I found a Stanley at a yard sale cheap and bought it for parts, thinking that I could get a couple of the rails etc. for the bosch jigs. After I got it home and found that all it needed was a couple of new pins and screws, I just used the parts list from the Bosch jig to get them. I agree that the compact box is a benifit as well The PC unit is at least twice as long. Joe

1. 
   clampman2 | Nov 11, 2002 05:44am | #17

   Joe,

   Thanks for the info. I didn't know that the parts were interchangeable. I made mine from scratch cause I enjoy playing with my new 6,000 lb. 1942 engine lathe. Also, my new pins are a better design than the ones that came with the jig, so they don't come out while I'm routing.

   Clampman

4. 
   riverr1 | Nov 10, 2002 01:50am | #15

   Imran,

   Another option that may or may not work for you is most rental places carry the jigs. Might give you an opportunity to test different makes.

   Don

1. 
   WW_wannabe | Nov 10, 2002 06:17am | #16

   More I think about it I may try my first door with a home made jig. But it does appear that Bosch is a good choice. I have also received responses stating that these jigs are not foolproof, which surprised me. The main reason I was exploring this was to avoid a mistake and also expedite the process.

   Thanks to all for the excellent suggestions.

   Imran