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Heres the Situation, I have a bunch of prehung doors with 5/8 radius hinges already installed. I will be replacing the hardware and the slabs only. I can either go square or 5/8's on the replacement hinges.

I am looking for a jig to simplify this process with cleaner results.
 

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If they are all the same and standard doors just make one. Take a 1/2" pc of plywood and cut rectangles into it the size of your hinges. Put a couple of blocks on it as stops that you use to align the jig and to clamp it to the door. Get a pattern router bit (top bearing) with a 5/8" diameter and you have yourself a nice useful jig. I've made a few of them for different size hinges. You only have to make them once. I make all of mine so I align the top of the jig to the door and it makes a 3/32" gap between the top of the door and the jamb.
 

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I use the porter cable set up. its worked great. have had it for about 10 years now. no problems.
The cheap plastic one? I have the same one, actually on my third. Only reason I have had to replace them is because I stepped on them they cracked. I think it is around $25 or $30 at HD, never had a single issue with it.
 

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The cheap plastic one? I have the same one, actually on my third. Only reason I have had to replace them is because I stepped on them they cracked. I think it is around $25 or $30 at HD, never had a single issue with it.
If you use the P.C. plastic one make sure the bearing on the router bit spins freely, else you'll melt your way into the jig. The better systems allow you to work more efficiently and are less prone to mistakes. More expensive of course.
 

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If you use the P.C. plastic one make sure the bearing on the router bit spins freely, else you'll melt your way into the jig. The better systems allow you to work more efficiently and are less prone to mistakes. More expensive of course.
Good point, I actually bought a Freud bit for mine and keep the PC as a back up. I may do a few doors at a time, typically its just a replacement front door or an interior door some angry teen put his fist through. If I was installing slabs all the time I would certainly spring for a better set up.
 
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