Doors and Windows - New interior doors

Hey:

We are going to replace all our interior doors, about 15 including closets. Anyway, I saw a jig that allows you to cut the hinges with a router a long time ago.
My question is, are these still available and if so what do they cost? Also, what router bit do I use?
Thanks for any and all help or suggestions.
Take care
Dan in Atlanta:)

You can find them at most any big box...I know HD carries Porter-Cable and Vermont American...the P-C includes a bit, but the template is nylon. The V-A has no bit, but the template is steel...

I bought the P-C and it worked just fine...I only did a few doors. The problem is you have to take it off and re-position for each hinge.

I just saw one in the Lee Valley catalog that might be better. It is adjustable for all 3 hinges and you can buy the bit for a bit extra...bout $75 total. Thats only about 2 x what you'd pay for the P-C at HD.

Good project! Let us know how it turns out.

Danno30008,

Why not just use prehung doors and be over it? With 15 doors, you'll spend 2 full days simply lining up the jig to mortise the hinges, PLUS the time to actually do the mortising. It will turn into a week long project. You could replace all 15 doors with prehungs in about 2 days, plus you're not spending $100 on a tool that you'll probably never use again.

I agree with Mike on the new prehungs. You will be getting a matching case and slab at the same time, just in case you stain instead of paint, and oh the labor savings. I have the tools in my arsenal to do the hinge mortising, but had rather take a virtual beating than do it. I always recommend prehungs. Besides the cost won't be that much more than just the slabs.

Well, when you consider the cost of prehings vs slabs...if i remember, its almost double..so that easily covers the cost of the tool. And he may have old trim or extra thick jambs he wants to keep. I believe most of the Box stores are only carrying paint grade jambs. Or maybe he doesn't want to repaint/stain the jambs.

My point is...lots of reasons to not go prehung.

And, I admit, lots of reasons to go prehung, so it's his choice

Also, with the tool from Lee-Valley, it might take 10 min to mortise each door.

First of all THANKS!

I didn't want to go to prehung because of the price and all th etrim work thaty I would have to take off and then put back on.:wall:
The doors are going to be painted, not stained and we are doing a room at a time, so this project will take a couple months or so.
I am going to get the fixture and practice on an old door that I have. I will let you know how I do on the first three in the morning.
Thanks again for all the help and take care
Dan in Atlanta

I sort of figured you were Atlanta by your username/zipcode. I live on the other side of Unicoi Gap from you. Good luck with the project, set your router accurately and take your time. Use a door buck to hold the doors vertically while you cut the mortises. You can make one from plywood and 2x4's.

Danno30008,

Since you are opting for the slabs, the router bit that you need is dtermined by the hinges that you'll be using. Whatever the corner radius of the hinge is, that's the bit you'll need.

Most common are 3/8" and 5/8". If the hinges have square corners, use whichever and chisel out the corner after routing.

Hi, A couple hints. Make sure you use a guide on the router, I've seen where some twit didn't and cut the guide. Read The directions Then practice on a old door. If you have the old doors use them for the pattern. Measure from the top down. That will tell you the lay out of the hinges. Once figure out the placement of the guide that will remain the same for the rest of the hinges an example the top of the guide goes six inches above the top of the hinge. Once you figure out the first one the rest are easy.
You will also need a hole saw 2 1/8 and a spade as small as you can use. I use 3/4 for an interior door.
You also will need a plane.
Good Luck Woodbutcher

Thanks again to everyone.

I did buy the Vermont guide that included a router bit.. Also, I plan on taking many practice cuts on a few old doors that I have around the basement. Actually going to read the directions on the router guide as suggested.. Think it will work better that way.
Got the white 6 panel inter doors at HD for only $19 each.. Kinda felt like I won the lottery.:)
Thanks again and take care
Dan in Atlanta

Sorry...just butting in here. I was at HD last night and saw those doors on sale. :D I wanted to buy all of them, for who knows what!...uh...but I didn't. Way cool price anyhow. :thumbup: If you haven't bought all the doors, you might want to look around in your area on craigslist. In my area and surrounding cities I've seen a lot either for free or cheaper. I just found and bought a 2 panel interior door for $15. I just saw yesterday at UCLA they were giving away for free, 200 brand new solid wood doors...but you'd have to take all of them and I had no where to store them.:rolleyes:

Anywho, have fun with your project :)

Hey everyone:

Just wanted to check in about this project.

Got the Porter jig at HD and took a while to read, yes, I actually read the directions. Then made about 10 cuts on the old door to get the feel of it and attacked the first door.

That one took almost 1.5 hours, start to finish.. The second one took right at 30 minutes and was a breeze.
Thanks again for all the help and I am glad I did not consider installing pre-hung doors.. Can't imaging what it would be like to take off and try to replace all that trim..:wall:
Take care

Dan