Adjustable Door Hinge Router Jig

UPDATE: 28/2/26 - Following a request, I have designed an add-on holder for router templates and uploaded the parts in an additional print profile. If you have already printed the jig, you will need to print the revised Back Rail because a small slot has been added to hold one end of the template holder. This was done to maximise the area available on the templates and strengthen the template holder. There are some additional photos which show the holder, template, and a centering insert.

I found that the back rail was lifting at one end during printing, so the profile has some modified settings to counteract this. I don't know if this was caused by using another roll of filament or by printing the part on its own, because cleaning the plate with detergent and water didn't solve the issue. On my P1S, I also closed the front door but kept the glass top sitting up in the riser.

I am in the process of uploading a parametric template generator so you can make templates for the Hinge Jig to suit your needs. The maximum cutout size in the template will be 89mm x 48mm. 

UPDATE: 12/2/26 - Uploaded a new profile, which contains updated parts and orientation of parts. While the original jig is still very useful, this version has a wider fence, an extra bolt holding down the Left Stop, and some changes to the shims to make them a little stronger. Thankyou to @geoffreycoan for his suggestions to improve the jig - hopefully these changes address most issues.

This adjustable router jig can be used for cutting hinge recesses into doors (clamped) and frames (hand held) using a guided router bit. I designed it because I need to hang a door for a family member, but I don't know the size of the hinges on the existing door. Trials have shown that it works well using a bit with a roller bearing the same size as the bit. Trials also highlighted that setting the router bit depth is critical, so I designed a couple of simple shims to assist in setting the bit depth. The design is based on the work of Bradshaw Joinery in a YouTube video that is well worth watching. The jig uses a couple of M4 bolts, nuts and washers to hold it together.

NOTE: In response to feedback, I've uploaded a wider version of the front fence, which might make it easier to clamp the jig in place.