Woodhaven 8663 User Manual
Parts List 8663:
Please identify and verify that you have all of the parts
listed below prior to assembly.
Part Description . . . . . . . . . . . Quantity
8663B Hinge Jig for SOSS 203. . . . . . . . . . . . . . . . . . . 1
4008 8” Double Track. . . . . . . . . . . . . . . . . . . . . . . . . 1
MF010 1/4-20 x 3/4" flat head screw . . . . . . . . . . . . . 2
5760B 1/4-20 oval nut . . . . . . . . . . . . . . . . . . . . . . . . . 2
8660T 2-7/8" One Track. . . . . . . . . . . . . . . . . . . . . . . . 2
MF001 10-24 x 5/16” flat head screw . . . . . . . . . . . . . 2
5750B 10-24 oval nut . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8663
SOSS 203 Hinge Jig
Owners Manual
Please Read Carefully!
BEFORE BEGINNING
Identify and verify that you have all the
parts listed. Read thru the instructions at least
once, familiarizing yourself with the parts and
their use before proceeding. You'll need a #2
& #3 Phillips screwdriver for assembly.
The 8663 SOSS Hinge Jig is designed to work
with a 3/4" bushing & locknut (our PN 5032K)
and a 1/2" upcut spiral bit (our PN 15407). If you
have your own 3/4" bushing, make sure the nose
isn't over 3/8" long. You'll need a plunge router
to cut the hinge mortises. The quality of the plunge mechanism
can effect the size of the mortise, resulting in a poor fit if the
plunge mechanism has excessive slop. Note: The pictures in the
instructions are of the 8663 SOSS 203 Hinge Jig, but all of the
SOSS Hinge Jigs assemble, and function, the same way.
ASSEMBLY
Insert the two 1/4-20 x 3/4" flat head screws (MF010) thru
the larger countersunk holes in the SOSS Hinge Jig (8663B).
Start a 1/4-20 oval nut (5760B - flat side first) on the end of
each screw. Slide the 8" Double Track (4008) on to the oval
nuts and in the groove in the underside of the Hinge Jig until
centered end-to-end, then tighten the screws. See fig. 1.
Insert the two 10-24 x 5/16" flat head screws (MF001)
thru the remaining two countersunk holes in the Hinge Jig and
start a 10-24 oval nut (5750B - raised side first) on the end of
each screw. Slide a 2-7/8" One Track (8660T) on to each oval
nut and in to the grooves in the underside of the Hinge Jig until
covering the oval nut, then tighten each screw. See fig. 1
Turn Page Over
SOSS 204
1
MF010 &
5760B x 2
4008
SOSS 203
8660-8664
SOSS Hinge Jig
MF001 &
5750B x 2
SOSS 101
SOSS 100
8660T
x 2
USAGE
The SOSS Hinge Jig has the correct setback built-in to it
for your SOSS hinge. Always index the face of the work against
the Double Track and an edge against the underside of the Hinge
Jig. The center of the Hinge Jig is 3-7/8" from each end. Use this
measurement to index your work along the Double Track and locate
where the hinge mortise will be cut. Clamp the work/Double Track
together in a vise, see fig. 2, or clamp the work in a vise and use bar
clamps to clamp the Double Track/SOSS Hinge Jig to the work.
2
3-7/8" ed g e
to center
The debris generated during cutting will interfere with the
bushing travel in the Hinge Jig. Make as many passes as needed,
cleaning out the debris between passes, until the cut is complete.
After installing the bushing and bit in your plunge router, set the
bushing in the opening in the Hinge Jig. Plunge the bit down until it
just touches the edge of the work and lock it in place.
CUT THE LONG/SHALLOW MORTISE FIRST
Place the mounting flange of the SOSS hinge
between the turret and the stop rod to set the plunge
depth for the long/shallow mortise. See fig. 3A.
Slide the One Tracks out until they are no longer
visible in the Hinge Jig opening, tighten the screws
and cut the long/shallow mortise. See fig. 4.
CUT THE SHORT/DEEP MORTISE LAST
Place the main body of the SOSS hinge (or a wood block
cut 1/32" longer) between the turret and the stop rod. Adjust
the stop rod so it's approximately 1/32" above the main body to
set the plunge depth for the short/deep mortise. See fig. 3B.
Loosen the two One Tracks and push them into the Hinge
Jig opening until they bottom out and are visible. Tighten the
screws and cut the short/deep mortise in 1/4" deep incremental
passes until you reach the full depth of cut. See fig. 5.
ACCESSORIES
ptional 4512 Fl ip St o p mounts on a 4016 16" Double Track
O
(minimu m le ngth reco m me nd e d) for qu icker p a rt index i ng a nd a l lows
setti ng t h e sto p up t o 6" f rom t he h i nge mortise, w ith a s pa ce r r eq u i re d for
dista nc e s les s t h a n 4-1/4". We recommend ed two Flip Stops, one for e a ch
side of the jig. Optional longer Double Tracks available to mount mult iple
jigs & s t o p s . Optional Self-Ce nt ering drill (6507 o r 650 9 ) centers itself in the
hinge sc rew mounting hole for a pe r fec tly c e nte r ed pi lot hole.
See fig. 6.
3
Mounting
Flange
4
3-7/8" ed g e
to center
A
B
Stop Rod
Main Body
Turret
©Copyright WOODHAVEN INC. 4/30/12
(800) 344-6657 or www.woodhaven.com
6
8663 SOSS Hinge Jig on 4016 16”
Double Track with two 4512 Flip Stops.
5
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