Brusso sell a mortis template for $36 LINK but I decided I didn’t want to part with $36 right now.
The first step was to cut out a negative of the Brusso template. I deleted the 1/4” divider and made my blank 1.004” by 1.254”. I made it oversized on purpose since it is a lot easier to shim the opening with masking tape than to file it to size
The next step was to build the template around the blank. The first layer was made from 1/8” Baltic Birch scrap. I used packing tape to hold these parts in place while gluing on the second layer
The second layer is 1/2” Baltic Birch scrap. These parts are laid out opposite the first layer. I spaced these parts back from the opening so that the second layer would not interfere with the rub collar.
I cleaned up both sides on the drum sander and marked the template for future reference.
The template is designed to use a 1/4” router bit with a 1/2” rub collar. After setting the router bit to the bottom of the template and used a 1/4” gage block to set the plunge depth.
After cutting a few test mortises, I shimmed the opening with four layers of masking tape on both the X an Y axis. The next step was to cut the mortise for the latch’s final installation.
Last I did a dry fit and waxed down everything I didn’t want epoxy on, removed the latch, applied the epoxy and installed the latch. Time for a hot shower and a relaxed evening watching the Texas Rangers thump the Indians.
-- Loyd, San Angelo, TX http:www.moorewoodenboxes.com