Question
I'm looking for a good manual system to set up for hanging residential doors. I plan to run job lots, so I don't want a door machine. I plan on 30 to 60 doors a month. Most of the advice I have gotten is that plywood jigs are the best. At 30 doors a day, look for a machine.
Forum Responses
(Architectural Woodworking Forum)
From contributor J:
The 'ole Bosch hinge template jig is a standard. Been using the same one for about 8 years now. Even has an adapter for a fourth hinge. From your post I gather you need to be portable. So any variation of the Bosch jig would probably work, especially if you're mortising both jamb and slab.
For new construction I've always used a collection of 4x4 and 3 1/2 in. templates, in 6/8, 7/0, and 8/0 sizes. Yes, it's more to carry around, but you don't have to set up the Bosch template, and you don't have to worry about hurting it. Plus, you don't have to worry about the hinge layout changing because you or someone else tapped the floor with the template! Yes, that happens. On production work, hanging that many doors, you'll want to feel free to move quickly, without worrying about your setup.
The Bosch template, at the same time, is indispensable for hanging new doors in old jambs, where hinge layouts vary throughout a home.
You can also get all your lock and latch jigs from Templaco. They have a boring machine as well, though you might find the Classic Engineering jig more to your liking. It's easier to switch between 2 3/8 and 2 3/4 backset, and no pins to lose when you switch back.
