While reading the April 2010 issue (FWW #211), I noticed how Doug Stowe set his router bit to the correct depth to cut a hinge mortise. Here’s another way that’s quick and accurate. It works on a plunge router equipped with a depth gauge.
First, chuck the bit in the router. Place the router on the workpiece and plunge the bit until it just touches the surface. Engage the plunge lock. Next, place a corner of the hinge on top of the depth-gauge stop and lower the depth-gauge rod on top of it. While firmly holding the rod down with finger pressure, lock the rod securely with the thumbscrew. Now you can release the plunge lock and set the hinge aside. The router is now set to cut a mortise to the exact thickness of the hinge.
This same basic technique, combined with a feeler gauge, can be used to add or subtract a bit of depth. To set the hinge proud of the surface, place a feeler gauge on the workpiece before lowering the bit to the surface. To set the hinge slightly below the surface, place the feeler gauge on top of the hinge before setting the router’s depth-gauge rod.

Drawings: Jim Richey

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