Soss Invisible Hinges by Joseph Soss

By: Soss  09-12-2011
Keywords: Wood, Door, Hinge

FIGURE 3 illustrates a typical door/jamb where SOSS Invisible Hinges will be mounted. Become familiar with the terminology as it will be used throughout these instructions.Jamb Preparation (Refer to Figure 4)
1
Remove the guide pins from the router guide template.2 Place the Router Guide Template on the hinge jamb so the locator pins rest flush against the pull side jamb face, and are on the inside of the intended door swing. The spacer tab should be flush against the head jamb, and positioned in line with the template (i.e. tab positioned as packaged).3 Once the desired position is established, the nails can be tapped-in the door rabbet to secure the template in place.FIGURE 4
4 REFER TO TABLE "A" to obtain the proper size drill or spade bit and starter hole depth.TABLE A: Starter Hole Depth
SOSS Hinge ModelDrill SizeStarter Hole Depth*
#101
#103
#203
#204
#208
#212
#216/#416
#218/#418
#220
¼"
3/8"
3/8"
3/8"
½"
½"
½"
½"
½"
37/64"
23/32"
27/32"
27/32"
1-1/32"
1-13/64"
1-9/16"
1-23/32"
2-1/8"

*The depth of the starter hole should be at least the values listed. Depths exceeding those tabulated will not adversely affect hinge operation.

5 Being careful not to nick or gouge the template, drill the starter hole for the router to the proper depth in the center of the hinge outline of the template.

Routing the Hinge Outline
6
The chart in TABLE "B" lists the maximum depths to which the hinge outlines should be routed. It is advisable to check the depth of the cut you are making prior to removing a significant amount of wood. If desired, the required depth may be obtained by making multiple router passes.

TABLE B Shallow Mortise

SOSS Hinge ModelRouter Bit SizeDepthRecommended Amana Tool Router Bit
#101
#103
#203
#204
#208
#212
#216/#416
#218/#418
#220
1/4"x 2-7/8"
3/8"x 3-1/4"
3/8"x 3-1/4"
3/8"x 3-1/4"
3/8"x 3-1/4"
3/8"x 3-1/4"
1/2"x 4-1/2"
1/2"x 4-1/2"
1/2"x 4-1/2"
7/32"
7/32"
3/16"
1/4"
9/32"
3/8"
15/32"
13/32"
15/32"
43838
46259S
46259S
46259S
46259S
46259S
51310
51310
51310

CAUTION: Do not exceed the listed depths when routing the hinge outline, as binding of the hinges will occur.

7 Using whatever means of measurement best suited to you, determine the location of the next hinge to be mounted on the jamb. Mark or measure that distance so as not to damage the door.

    NOTE: Remember the distances you have selected, as you will need to recall those measurements when mounting the templates on the door.

8 Remove the template from the jamb and move it to the new location you have chosen, repeating steps 2 through 7 for the number of hinges requiring installation.

Door Preparation (Refer to Figure 3)

1

Prior to mounting the template on the door, make certain that the door is properly oriented.

2 The clearance between the head jamb and the door is set with the spacer tab. It should be positioned one quarter turn so the template will hang from the top of the door.

3 Place the Router Guide Template on the door so the locator pins rest flush against the pull side face of the door, and are on the inside of the desired direction of the door swing.

4 Once the desired position is established, the nails can be tapped in to secure the template in place.

5 Again, being careful not to nick or gouge the template, drill the starter hole for the router to the depth listed in TABLE "A" in the center of the hinge outline of the template.

6 The chart in TABLE "B" lists the maximum depths for which the hinge outlines should be routed. It is advisable to check the depth of the cut you are making, prior to removing a significant amount of wood. If desired, the required depth may be cut in multiple passes.

7 Recalling the measurements you made to determine the hinge spacing on the jamb, use those identical measurements to position the template for the next hinge mortise on the door.

8 Remove the template from the top of the door and move it to the new location repeating steps 3 through 7 for the number of hinges requiring installation.

At this point, the routing of the outline portions of the hinge mortises is complete. The next step is to rout the deep mortises.

Place the guide pins into their proper holes on the template. The guide pins are threaded and must not be hammered or otherwise forced into position. Care must also be taken that the threaded guide pins are not overtightened, as this may distort the templates.

Completion of the Jamb Mortises (Refer to Figure1)
1
Starting at the top hinge mortise, position the template so the nails fit into the holes left in the jamb from the previous rout. The locator pins should be toward the inside of the door swing as before.2 Once the proper position is reestablished, the nails can be tapped in to secure the template in place.3 To complete the routing of the hinge mortise, it will be necessary to remove wood to the depth listed in TABLE "C". It is recommended that multiple passes be made, as opposed to removing all of the wood at once.
#101
#103
#203
#204
#208
#212
#216/#416
#218/#418
#220
33/64"
21/32"
25/32"
25/32"
31/32"
1-9/64"
1-1/2"
1-21/32"
2-1/16"

CAUTION: Rout only the area between the guide pins. Do not remove any more material from the circular outline or any outside the guide pins.

4 After the deep mortise has been routed, remove the template.

5 Place a SOSS Invisible Hinge into the mortise you have completed and inspect the following:
A Does the hinge fit "snugly" into the mortise.
B Does any portion of the hinge extend beyond the rabbet of the jamb?
The body of the hinge should fit snugly into the mortise. If the hinge body extends above the jamb after the hinge has been pushed into the mortise as far as possible, verify that the mortises have been routed to the proper depths. Correct as required.

6 Position the template at the next location on the jamb. Repeat steps 1 through 5 for the number of hinges requiring installation.

Completion of the Jamb Mortises (Refer to Figure1)
1
Position the template so the nails fit into the holes left in the door from the previous rout. The locator pins should be toward the inside of the door swing as before.

2 Once the proper position is reestablished, the nails can be tapped in to secure the template in place.

3 To complete the routing of the hinge mortise, it will be necessary to remove wood from the door to the depths listed in TABLE “C”. Again, it is recommended that the wood be removed by making multiple router passes.

4 After the deep mortise has been routed, remove the template from the door and position it at the next hinge location on the door.

5 Repeat steps 1 through 4 for each hinge requiring installation.

Mounting the Door to the Jamb
Having completed the routing of the hinge mortises, notice that the hinge mortise is not centered within the thickness of the door. The "thin" section corresponds to the inside surface of the door.

1 Place the SOSS Invisible Hinges into the mortises so the hinge bodies straddle the thin section of the door. Using the wood screws supplied with the hinges, secure the hinges to the door.

2 The door can then be moved into a position where the remaining hinge bodies can be placed into their respective mortises in the jamb.

3 Secure the jamb side of the hinges with the remaining wood screws.

4 Exercise the door to see that it opens and closes freely throughout the required amount of opening.

Keywords: Door, Hinge, Invisible Hinges, Wood

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