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Cutting spaces for a set of door hinges is not as complicated as it might seem. DIY enthusiasts can cut door hinges successfully with a Dremel, an appropriate router bit, and some elementary knowledge of door hinge placement. The following information should assist you to perform this task effectively.
How Do You Cut Door Hinges With A Dremel?
Cut door hinges by measuring 5 to 6 inches from the top of the door and 7 to 9 inches from the bottom, then place the hinges in position and trace their outline with a pencil. Score the marking with a utility knife, and finally, cut the recess for each hinge carefully using a Dremel fitted with a straight bit (1/8 inch, size 650).
Step 1: Gather Tools And Accessories
The first step is to gather the requisite tools and accessories to cut the door hinges with the Dremel.
In addition to a properly-functioning Dremel rotary tool, you will need:
- A suitable router bit (see Step 2 below)
- A ruler or tape measure
- A utility knife
- A pencil
- Protective goggles
- Cut-proof gloves
- Medium grit sandpaper (optional)
Step 2: Select Suitable Dremel Router Bit
Selecting a suitable router bit is essential for cutting door hinges successfully with the best Dremel tool. It is also useful on installing overlay cabinet hinges.
Choose a straight Dremel bit. A straight bit is optimal since you will make straight-sided, flat-bottomed trench grooves or recesses in the door so the hinges can sit flush with the wood surface.
| Types of Router Bits | Ideal Application |
| Straight router bit | Cuts straight, square-bottomed grooves |
| Dovetail router bits | Cutting a series of pins along one piece of material |
| Flush Trim router bit | Cutting around a surface’s edge |
The standard Dremel router bit size for installing door hinges is 650 (1/8 inch) However, it is generally fine to select a 652 (3/16 inch) or 654 (¼ inch), though it requires more skill to wield these larger bits with the necessary accuracy.
For safety reasons, it is essential to attach the bit to the Dremel chuck securely so it does not detach dangerously when the tool starts spinning.
Step 3: Measure And Mark The Hinge Positions
Place the door with the working side facing up.
Use a ruler or tape measure to take the necessary measurements so you can identify the correct position for the hinges on the door.
The standard recommendation is to measure 7 to 9 inches from the bottom of the door, and 5 to 6 inches from the top. For the sake of simplicity, it is acceptable to make the upper and lower measurements the same (6 inches should be fine).
Consider whether the door has a hollow or solid core. If the door has a hollow core, two hinges are sufficient. For solid core doors and exterior doors, the general rule is to use three hinges. In this case, find the position for the additional hinge by measuring the halfway point between the top and bottom hinges.
Take a pencil and mark the measurements with a line (across the width of the door). It is also advisable to mark the thickness of the hinge on the side of the door so you know how deep to cut the recess with the Dremel.
It is worth noting that if you are installing the door in a new wood frame, you will need to repeat the procedure on the side jamb.
Step 4: Trace The Hinge
Open the hinge and place the mobile leaf (the side of the hinge you are fixing to the door) in the marked position on the side of the door. Trace the three-sided outline of the hinges with a pencil.
A helpful tip is to offset the hinge leaf slightly so there is a small space between the barrel of the hinge and the side of the door. This will prevent the barrel from scraping against the door and allow it to move freely.
If you are also cutting a mortise for the wood door jamb (frame), perform the same process but trace the outline of the fixed leaf of the hinge.
Step 5: Score The Traced Outline
Use a utility knife (or carbide scoring knife) to score the door along the traced outlines of the hinge’s mobile leaf.
Score the outline three or four times until the depth of the groove is roughly the same as the thickness of the hinge.
Once again, repeat the scoring procedure if you need to cut a recess for the hinges in the wooden door frame.
The purpose of scoring the outline is to enable a cleaner, more accurate cut with the Dremel. Making a scored groove defines the outline more precisely. Crucially, scoring creates a razor-thin kerf along the perimeter, negating the need to move the Dremel bit right up to the edge of the outline (and risk cutting beyond the mark).
Step 6: Wear Protective Gear
Put on safety goggles and cut-proof gloves before proceeding. Dremels are relatively small tools but are sufficiently powerful to shoot wood fragments into the air, especially when you cut a metal using a Dremel, so it is essential to wear protective eyewear!
Step 7: Execute The Cut With The Dremel
Now you can use the Dremel to cut out the recesses for the hinges.
Turn on the hand-held, multi-purpose rotary tool, and start cutting into the wood. Follow these tips for ensuring precise and neat cuts.
Tip 1:
Always apply gentle and even pressure while cutting. Never force the router bit into the wood because this might cause chipping or splintering, which might disfigure the door (or frame) and pose a safety hazard.
Tip 2:
It is also imperative to cut slowly, especially at the start and end of the process. Do not rush the cut because you might cut outside the lines. Cutting too fast also poses the risk of making the mortise too deep.
Tip 3:
When it looks like the cut is complete, insert the hinge (without screwing it in) so you can check the size and depth of the mortise are correct. Ideally, the recess should be slightly deeper than the thickness of the hinge.
Step 7: Smooth Uneven Parts With Sandpaper (Optional)
If there are any uneven edges, it might be worth using some medium grit sandpaper to create a smooth, neat finish.
Frequently Asked Questions
How Do You Cut A Door Hinge By Hand?
You can cut a door hinge by hand using a good framing hammer and chisel to cut the mortise. Follow the process described above, but cut the recess by softly hammering the chisel blade at a 45-degree angle.
The chisel cuts should be shallow and executed against the wood grain in a series of parallel slices.
What Chisel To Use For Hinges?
A spring-loaded corner chisel is the optimal chiseling tool to cut mortises for door hinges. You can also use a standard flat carpentry chisel (about 1¼ inches wide) for hinges (though it does not cut as rapidly or easily as its spring-loaded cousin).
What Tool Is Used To Cut Hinges In Cupboard Doors?
A Dremel with a straight bit (650 size) is often used for cutting hinge mortises for cupboard doors. Another common tool for mortising cabinet door hinges is a power drill fitted with a hinge cutter bit.
Do Doors Come With Hinge Cutouts?
Pre-hung doors (which are sold together with the frame) come with hinge cutouts, so you do not need to cut your own. In contrast, slab doors (sold without the frame) do not have hinge mortises. So, if you have a slab door, you will need to cut recesses for the hinges before installation.
What Is The Best Dremel Speed For Cutting Wood?
When cutting wood with a Dremel, it is best to use one of the tool’s highest speed settings – anything from 12 000rpm to 30 000rpm works effectively).
The ideal speed will, however, depend on the Dremel model, the bit, and the hardness of the wood, so experimentation is necessary (start slow and gradually increase the rpm).
Conclusion
Cutting door hinges with a Dremel is not overly complicated and does not require sophisticated tools or advanced knowledge and skills. One traces and scores the outline of the hinges on the door (and the frame is necessary), and then uses a Dremel and straight bit to cut the recess (or mortise) for the fittings.
