Brusso Quadrant Hinge Mortising Jig

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Project by mwill87428 posted 02-22-2013 01:28 AM 4294 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


690 posts in 2505 days

#1 posted 02-22-2013 01:39 AM

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, Chesapeake, VA

View mwill87428's profile


40 posts in 1741 days

#2 posted 02-22-2013 03:06 AM

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


116508 posts in 3392 days

#3 posted 02-22-2013 06:16 AM

Good idea well done

-- Custom furniture

View mariva57's profile


664 posts in 1819 days

#4 posted 02-22-2013 10:19 AM

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


2208 posts in 2954 days

#5 posted 02-22-2013 10:34 AM

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


235 posts in 2094 days

#6 posted 02-22-2013 10:57 AM

What a great idea

-- I have the Saw Dust Fever

View 489tad's profile


3242 posts in 2827 days

#7 posted 02-22-2013 11:15 PM

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


40 posts in 1741 days

#8 posted 02-22-2013 11:41 PM

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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