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Prepare for fixing
With the hinges now in place, mark the position of the screw holes, but before inserting the screws, use a bradawl to form pilot holes that will assist correct insertion of the screws and help prevent the timber from splitting. For 75mm hinges, use number 7 gauge, 25mm screws
The Transfer
Next, you need to transfer the position of the hinges from the door onto the door casing, so that when the hinges are recessed into the casing they correspond with the door and, at the same time, position the door so that the top gap is 2mm.
There are two methods that can be used:
1. Using a Staff
You could use a staff with a square cut end, (a length of timber, 25mm x 10mm for example) 2mm longer than the door's prepared length.
Using a square, draw a line 2mm down from the top of the staff, and place the staff onto the door edge, with the 2mm mark to the top corner of the door's edge (the 2mm excess will overhang). This overhang provides the required 2mm 'top gap' for when the door is hung. Holding the staff in this position, mark the position of the hinges onto it.
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Now, place the staff onto the door casing where the hinges are to be fitted, with the top tight up to the casing head, and using a sharp pencil, carefully transfer the marks from the staff to the door casing.
2. Using the Door
Alternatively, you could use the door as your 'staff'. By placing the door in the opening and with the aid of wedges, set the door to the correct position, raising it so that the top gap is 2mm. With the door held in this position, mark the position of the hinges from the door directly onto the door casing.
Lines can now be drawn, about 20mm long from the marks, which should be square off the casing.
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Hinge Position
The next step is to position the vertical lines between the two horizontals that have been drawn for each hinge, as when fitting the hinges to the door. However, in this case, not only does this line mark the position of the hinges, it also governs the position of the door when closed in relation to the shoulder of the rebate. If set too far in towards the shoulder of the rebate, the door will rub against the shoulder preventing it from from closing properly. If not set in far enough towards the shoulder of the rebate, the gap between the shoulder and the face of the door will be too wide when the door is closed. Getting this position correct is actually quite simple, and achieved by measuring the exact distance from the edge of the door to the edge of the hinge as shown here on the left. In addition to this, because there must be a clearance between the door and the shoulder of the rebate, an additional 2mm should be added to the measurement for free movement and an allowance for the build up of paint on both surfaces. This measurement should then be transfered to the |
door casing. Do the same with the second and third line and join these two points by drawing the vertical line.
Cutting Out the Casing
Using the same procedure as with the door, cut out the recesses for the hinges into the door casing, testing the fit as you proceed. Having a spare hinge for this job is also a good idea.
Hanging the Door
With the door in the open position, raise it up so that the open hinges correspond to the recesses that you have formed in the door casing. Beginning at the top, ensure that the top hinge fits correctly up to the vertical line, and with a bradawl, make a pilot hole for one screw only, preferably the centre, and inset the screw. Do the same for the bottom hinge, but do not at this point insert the remaining screws as the door may need slight adjustments.
Try closing the door and check for fit, in particular the distance from the closed door surface to the rebate shoulder. Secondly, check the overall fit to the sides and top. If you are happy with the fit, inset the remainder of the screws and try again. |
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If it is found that after inserting all the screws that the vertical gaps are no longer equal, ie, the 2mm hinge side gap has been reduced and the latch side gap increased. This indicates that the hinges are set-in too deep, and adjustments to correct it must be done via the hinges by packing them out slightly, rather than by any other means.
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