I am going to attempt to turn this interior door into a split door (aka Dutch door). It is solid wood and has enough room above the door handle and below the window panes to do so.
Part of doing so is adding a 4th hinge. I have a matching hinge ready to go. What I need advice on is how to recess the hinge base like the existing hinges. I don’t know that a router will work, due to the space constraints. Based on the picture, suggestions on how to remove the necessary amount of wood?
I have a pattern somewhere that was my dad's. Put it on the door where the hinge would go, smack it with a hammer and it makes an outline the right size and depth, then just chisel it out.
Of course since you have the new hinge, you could just trace and chisel it.
If I can find it I'll lend it to you, but they're probably cheap at Lowe's depot or online.
Have a long reach bit on the router? You could build up a flat surface for it to ride on above the trim piece.
Otherwise, a chisel and some time.
Wood chisel. Outline hinge with pencil, chisel straight in with your taper toward the part you’re removing, chisel out center. You’re not actually whacking the chisel after the initial straight in cuts, a proper wood chisel is sharp enough to cut the mortise for a hinge without a hammer.
This is one of those situations where a sharp chisel is the fastest and most accurate way to go.
But I mean sharp. Not I just bought it and pulled it out of the package, I mean you can literally shave with it sharp.
Patrick posted whilst I typed. We are on the same page.
Yup, hammer and chisel. That's how I've done it
2nd the hammer and chisel. A router will walk, like it did in your pic. Even with a jig a router isn't worth the trouble.
Just wanted to jump on the chisel bandwagon here. It's not all that hard to do and get a good result without experience doing this. You should easily be able to make a cleaner mortise than the one pictured above.
I'm guessing my post is superfluous but: chisel.
The picture you posted shows a half mortised hinge. It's in a mortise about twice as deep as it should be.
A conventional hinge looks like this: 
With the hinge basically flush with the wood in the jamb and the door. This installation provides support for the door that the half mortised hinge does not. IMHO it's worth the effort to switch the hinges to conventional, because now you only have two hinges on each panel. Plus it's the "right way".
You want to get square corner hinges to make it easier to mortise with your sharp chisel. Youtube will help.
The picture shows a Non-mortise hinge in a jam that hasn't been mortised and a door that's, shall we say, over mortised. I would go one way or the other i.e. mortises all around, or no mortises. To me it looks like you're stuck mortising the jam because the door is mortised, in which case you would need different hinges. And a chisel. good luck.
I know a pencil works, but I like using a hinge marking gage...
If you need to match the above photo, just use an axe.
Alternatively, buy a subscription to This Old House website and watch Norm do it.
There was an Ask This Old House show quite recently where Tom made a dutch door for a homeowner. It was more involved than just sawing the door in half.
bustedplug said:The picture shows a Non-mortise hinge in a jam that hasn't been mortised and a door that's, shall we say, over mortised. I would go one way or the other i.e. mortises all around, or no mortises. To me it looks like you're stuck mortising the jam because the door is mortised, in which case you would need different hinges. And a chisel. good luck.
This is all true, the easiest way to go is match what’s there provided it works as is. In my brain, as a carpenter, i’m seeing the door crashing into the jamb on the hinge side with a non mortise hinge set in a mortise before it’s fully closed, but if it’s currently working then run with it. Just mount the other hinge before you cut anything. I’d be cutting a 1” section out of the door and capping the top with a 1x to finish it/lean on.
In reply to Streetwiseguy :
That video is awesome! Thank you for sharing that. The good news for me is that this is an interior door. I’m fine with a gap in the middle of the door that is the width of my saw blade.
As for the hinge, it is the jamb that has been cut (mortised is the term I guess?). My goal is to add a 4th hinge, installed in the same manner. I will go the chisel route, based on the recommendations and the video.
More pictures in case they help.
I assume you'll be securing the upper half to the lower half with a simple barrel bolt.
It does look nicer to put a small shelf on the lower half for when it's closed and the top is open. I've modded a half dozen or so doors at work this way.
Make sure that hinge #4 lines up perfectly with the other three or they will bind/squeak and not swing properly.
KyAllroad (Jeremy) said:I assume you'll be securing the upper half to the lower half with a simple barrel bolt.
It does look nicer to put a small shelf on the lower half for when it's closed and the top is open. I've modded a half dozen or so doors at work this way.
Make sure that hinge #4 lines up perfectly with the other three or they will bind/squeak and not swing properly.
Yep. Some sort of simple slide lock to mate the top to the bottom. I hadn't thought about 'finishing' the top of the lower half. Once I get the two parts functional, I'll let my wife decide how she wants to handle that portion of the project!
In reply to dyintorace :
It is really hard to ask a home repair question that hasn't been answered by Norm, Tom or Richard.
Well, where are you going to cut it?
To leave enough wood at the bottom of the top portion, you are cutting where the lockset is, or below it. So if you are going to fill the hole and relocate the lockset, then you are in the "While I'm in there" mode and should definitely change the hinges.
I can't remember the name for them, but those hinges are the style that only need to be mortised into either the door or as this case the jamb. The part of the hinge that is fastened to the door fits into the cut out on the other side of the hinge when the door is closed.
Sorry if it's already been mentioned, I am on my phone and can't see all the pics or posts, getting old sucks.
But get the hinges situated before you cut the door.
Ask me how I know.
SaltyDog said:Sorry if it's already been mentioned, I am on my phone and can't see all the pics or posts, getting old sucks.
But get the hinges situated before you cut the door.
Ask me how I know.
Duly noted!
Progress! 4th hinge is installed. I’m going to reinstall the door next so I can get the new hinge positioned. I’ll then pull the door back off and make the cut!
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