Brusso Quadrant Hinge Mortising Jig

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Project by mwill87428 posted 526 days ago 2204 views 10 times favorited 8 comments Add to Favorites Watch

I am building a box and needed to make a jig for mortising Brusso quadrant hinges into the sides and top of the box. After looking at Brusso’s jig on the website I came up with this. With this jig you clamp the box and lid together and do both mortises at one time. It seemed to work ok but was a little clumsy clamping everything together. The lid closes so I guess it’s ok.

-- Max

8 comments so far

View AlBCuttnWud's profile


496 posts in 1296 days

#1 posted 526 days ago

Nice job. I will admit I did a box a while back and was intimidated about using these hinges. I had thought about making a jig too but just didn’t have the time to make. You have inspired me now so I guess I need to get to work on a jig.

If you don’t mind me asking, how did you get your jig hole cut out?

-- -Al, Patuxent River, MD

View mwill87428's profile


31 posts in 532 days

#2 posted 526 days ago

Thanks. It seemed to work ok and I like the idea of machining both pockets (box & lid) together. I have a milling machine and I cut the pocket there.

-- Max

View a1Jim's profile


112002 posts in 2183 days

#3 posted 526 days ago

Good idea well done

-- Custom furniture

View mariva57's profile


423 posts in 610 days

#4 posted 525 days ago

Great jig, solved the problem for the mortise hinges

-- The common man thinks. The wise man is silent. The stupid man discusses.

View Diggerjacks's profile


1738 posts in 1744 days

#5 posted 525 days ago

Hello mwill87428

Great jig well done

Thanks for sharing

-- Diggerjack-France ---The only limit is the limit of the mind and the mind has no limit

View Bill_N's profile


234 posts in 884 days

#6 posted 525 days ago

What a great idea

-- I have the Saw Dust Fever

View 489tad's profile


2230 posts in 1617 days

#7 posted 525 days ago

Pretty slick. I made a right and left side jig. It worked ok but your jig is better.

-- Dan, Naperville IL, I.G.N.

View mwill87428's profile


31 posts in 532 days

#8 posted 525 days ago

I could have made a fixture to mount both parts (box and top) on the mill table but it would have been a much more complicated project because of the great difference in the thickness of the box and top. The portion of the fixture that mounted the top would have to be adjustable (if you wanted to use it for other boxes) to get the closing surfaces of both parts in the same plane for machining. I think that the way I did it is a much simpler solution because you just lay both parts on the bottom plane of the fixture, clamp up and route. This jig only took about 30 minutes to make. If I was manufacturing boxes by the hundreds and using the Brusso 638 exclusively then I might consider doing it the other way in the mill.

I kind of rambled on here, I hope this makes sense.

-- Max

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