Continued:

Fig. 2

Mill a piece of 4/4 maple or birch lumber to about 3-1/2" wide and a length of about 18" for use as a clamping board.

On the previous page we calculated the width of the spacer block (B) to be 1-1/4" wide.  That dimension is 1/8" less than the thickness of our door. The clamp board needs to be placed such that the mortise will be centered on the door. We need to add another 1/16" to the width of blocks (B) to properly space the clamp board.  You can either plane a piece of lumber 1/16" thick to use as a spacer or, go down to the hardware store and look in the metals section for 1/16" brass bar stock.  If you buy the brass bar stock you will have enough for several shims.  I recommend that you cut off at least two about 6" long use them on this project and save them for later use.

At this time remove one of the blocks (A) from the base of the jig, being careful not to disturb the remaining blocks.  With the 1/16" shims in hand place them between the blocks (b) and the clamp board.  Use clamps to hold the assembled parts in place while you turn the jig over and drill pilot holes for screws to hold the jig base to the clamp board.

Remove the remaining guide blocks and sand off all of the sharp edges.  Finish with a coat of clear Watco Danish oil and enjoy cutting perfectly centered mortises for lock bolts whenever necessary.

Any questions or comments contact me.

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