help with latch hinge mortises

[Jaysen]

A little secret...

If you have the proper radius bit, you don’t need to radius the template. Just make the corner straight extension of the edges. The bit will make the rounded corner for you.

So figure out the diameter of the hinge corner radius and make it simple by buying a bit to match.

That would def simplify things. I fear that 1-5/16 may not be an easy-to-find mortise bit size.

Fostner bit and drill press?

For some reason I thought these were square with rounded corners. I’m no help at this poin

[VT_Jeff]

For some reason I thought these were square with rounded corners. I’m no help at this poin

I wasn't that smart or maybe I was too cheap. The whole end of the hinge is a radius, 1-5/16.

[Jaysen]

For some reason I thought these were square with rounded corners. I’m no help at this poin

I wasn't that smart or maybe I was too cheap. The whole end of the hinge is a radius, 1-5/16.

If you’ve access to a woodcraft or other stupidly expensive woodworking shop they should have a fostner that size. You will need a press for that but...

With a diameter that big the pattern and collar solution is probably the easiest.

[Evan_Gatehouse]

Because I am not a wood worker - I'd make the recesses slightly oversided. Then drill and fill oversized mounting holes with epoxy plugs. At the same time, cover the hinge with brown mylar packing tape. Fill the gap between the oversized holes and the hinge with thickend epoxy. Perfect fit.

Bonus - you have to seal the bare wood with at least 2 coats of plain epoxy otherwise. This does it in one application.

[Jaysen]

Because I am not a wood worker - I'd make the recesses slightly oversided. Then drill and fill oversized mounting holes with epoxy plugs. At the same time, cover the hinge with brown mylar packing tape. Fill the gap between the oversized holes and the hinge with thickend epoxy. Perfect fit.

Bonus - you have to seal the bare wood with at least 2 coats of plain epoxy otherwise. This does it in one application.

This. Voice of experience. Simple solution.

[VT_Jeff]

Because I am not a wood worker - I'd make the recesses slightly oversided. Then drill and fill oversized mounting holes with epoxy plugs. At the same time, cover the hinge with brown mylar packing tape. Fill the gap between the oversized holes and the hinge with thickend epoxy. Perfect fit.

Bonus - you have to seal the bare wood with at least 2 coats of plain epoxy otherwise. This does it in one application.

Great thoughts Evan. I do a lot of the "tape and fill" procedure you mentioned but had not seriously considered it here. I think I was stuck on my original plan of getting the mortises cut correctly into the wood and I lost sight of the larger goal, which is just to get the hinges flush/clean. I'm going to re-tool in that direction.

[VT_Jeff]

Because I am not a wood worker - I'd make the recesses slightly oversided. Then drill and fill oversized mounting holes with epoxy plugs. At the same time, cover the hinge with brown mylar packing tape. Fill the gap between the oversized holes and the hinge with thickend epoxy. Perfect fit.

Bonus - you have to seal the bare wood with at least 2 coats of plain epoxy otherwise. This does it in one application.

This. Voice of experience. Simple solution.

Yup. Just another day at BBCU!

[cape_fisherman]

Spend the time making a jig & then router 100%

[VT_Jeff]

Spend the time making a jig & then router 100%

That's the path I chose, finished today. there are photos and a description on my build thread.

Although I liked the concept of over-cut and backfill, I was concerned about my ability to get it right 8 times in a row. I knew the router/template option would be the easiest to repeat, and it was. The template was super easy to make with a forstner bit that exactly matched the hinge radius/width, 30 mm. Just f few hits with the drill press and a little filing and it was done and about flawless.

Credit to Fallguy for initially pushing me in that direction, appreciate it.

[Jeff]

Great work Jeff!!!! Jeff