CA3175254A1 - Jig for use in configuring a door for receiving a door latch assembly and door handles - Google Patents

Abstract

A jig for use in configuring a door for receiving a door latch assembly and door handles comprises a first side member for secure engagement with the first face of the door. The first side member presents a face borehole cutting guide surface for guiding a hole saw for cutting a face borehole into the door at the first face of the door. A second side member is for secure engagement with the second face of the door. The first side member and the second side member are interconnected in spaced relation each from the other by movable connectors so as to define a door-receiving channel therebetween. An edge borehole cutting guide is supported by at least one of the first side member and the second side member to thereby accurately position the edge borehole cutting guide at the side edge of the door, for guiding a hole saw to accurately cut an edge borehole in the edge of the door. A latch plate mortise cutting guide is supported by at least one of the first side member and the second side member to thereby accurately position the latch plate mortise cutting guide at the side edge of the door, for guiding a router to accurately cut a latch plate mortise in the edge of the door.

Description

JIG FOR USE IN CONFIGURING A DOOR FOR RECEIVING A DOOR LATCH ASSEMBLY
AND DOOR HANDLES
FIELD OF THE INVENTION
[0001] The present invention relates to jigs and more particularly to jigs for use in configuring a door for receiving a door latch assembly and door handles, and even more particularly for guiding the cutting of boreholes and a latch plate mortise in a door to permit installation of a door latch assembly and door handles.
BACKGROUND OF THE INVENTION

[0002] In order to install door handles on the opposed faces of a conventional vertically oriented hinged door and a door latch assembly at the vertical side edge of the door, a face borehole must be cut accurately in a proper location, typically by use of a hole saw in both first face of the door to the second face of the door. The face borehole extends through the door from the first face of the door to the second face of the door. Also, an edge borehole must be cut accurately in a proper location, typically by use of a hole saw. The edge borehole extends from the side edge of the door to the aforementioned face borehole. Further, a latch plate mortise must be routered accurately in a proper location on the side edge of the door, around the edge borehole. More specifically, the face borehole should be the correct distance in from the side edge of the door, and should be as close as possible to the correct elevational height Date Recue/Date Received 2022-09-22 such that the latch of the door latch assembly installed on the door properly aligns with the co-operating opening in the strike plate that is secured to the door frame.
Further, the edge borehole and the latch plate mortise should be as close as possible to the center of the door between the two faces of the door, and should be as close as possible to the correct elevational height such that the latch of the door latch assembly installed on the door properly aligns with the co-operating opening in the strike plate that is secured to the door frame.

[0003] It has been found through significant experience that known prior art jigs, which happen to be the most commonly used and considered to be the best jigs available on the market, not do not readily permit the accurate alignment and the formation of the face borehole.
Further, they do not provide for the guidance of the cutting of the latch plate mortise in the edge of the door. Also, the jigs are not modular in nature and do not readily properly accommodate guiding the hole saw that is used to cut the borehole in the door, thereby typically causing the borehole to be cut inaccurately. They also do not seat properly on the three-degree bevel of the vertical edge of a door. Further, they do not accommodate the formation of the latch plate mortise using a router.

[0004] One relevant prior art patent is United States Published Patent Application No.
2005/0220548, published October 6, 2005, to Thomas et al., and entitled Door Lock Set Installation Jig. This patent document discloses an installation jig that has a body member and a clamping mechanism. The clamping mechanism along with the body are clamped onto a door. The body includes a plurality of walls with one wall having an aperture enabling passage of a tool which may drill a hole into a door at a desired standard lock set size. Also, the body Date Recue/Date Received 2022-09-22 includes an aperture to enable a lock bolt hole to be drilled into the door at a plurality of standard door thickness.

[0005] One relevant prior art patent is United States Published Patent Application No.
2005/0220549, published October 6, 2005, to Thomas et al., and entitled Door Lock Set Installation Jig. This patent document discloses an installation jig has a body member and a clamping mechanism. The clamping mechanism along with the body are clamped onto a door.
The body includes a plurality of walls with one wall having an aperture enabling passage of a tool which may drill a hole into a door at a desired standard lock set size.
Also, the body includes an aperture to enable a lock bolt hole to be drilled into the door at a plurality of standard door thickness.

[0006] Another relevant prior art patent is United States Patent No.
10/323,421, issued June 18, 2019, to Gold et al., and entitled Template for a Router to Notch a Door Latch Slot.
This patent document discloses a template for a router to notch a door latch slot. The template comprises a jig that is adapted for use in routing slots in door slab such that the door slab can receive a latch. The template for a router to notch a door latch slot is clamped to the door slab such that an aperture formed in the template for a router to notch a door latch slot is positioned over the lock rail of the door slab. The aperture can then be used as a template for the router to create a door latch slot to receive the latch plate of the door lock. The template for a router to notch a door latch slot comprises a "U"-channel, a pressure plate, and a thumbscrew.

Date Regue/Date Received 2022-09-22

[0007] Another relevant prior art patent is United States Published Patent Application No. 2008/0089752, published April 17, 2008, to Rusiana et al., and entitled Mounting Jig Assembly for a Door Latch. This patent document discloses a mounting jig assembly for mounting a door handle to a door having a main door bore. The mounting jig assembly includes a drill jig constructed and arranged for placement on the door over the main door bore and having at least one mounting hole. The drill jig is constructed and arranged for engaging a door latch at more than one location.

[0008] Another relevant prior art patent is United States Patent No.
6390,738, issued May 21, 2002, to Frid man, and entitled Tool Jig for Doors. This patent document discloses a drill jig for use in forming a door. The tool jig comprises a pair of jaws that clamp onto the edge of a door. The clamp is first attached to the edge of the door by a spring load and then further secured by a cam which the workman turns to apply additional clamping force. A
center block between the jaws has a guide hole for drilling the lock hole in the edge of the door. The centerline of the center block is perpendicular to the centerline of the knob hole and is positionable to permit location of the knob hole at either one of two locations depending on the style of the lock set. The center block is hingably attached to both jaws of the clamp such that guide hole for drilling the lock hole is always centered between the jaws.

[0009] It is an object of the present invention to provide a jig for use in configuring a door for receiving door handles and a door latch assembly.

Date Regue/Date Received 2022-09-22

[00010] It is an object of the present invention to provide a jig for guiding the cutting of a face borehole through a vertically oriented hinged door from the first face to the second face of the door to permit installation of door handles, and an edge borehole and a latch plate mortise in a vertically oriented hinged door to permit installation of a door latch assembly at the vertical side edge thereof.

[00011] It is an object of the present invention to provide a jig for guiding the cutting of a face borehole through a vertically oriented hinged door from the first face to the second face of the door to permit installation of door handles, and an edge borehole and a latch plate mortise in a vertically oriented hinged door to permit installation of a door latch assembly at the vertical side edge thereof, wherein the face borehole is cut in a proper location between the two faces of the door, and the edge borehole is cut and the latch plate mortise is routered in a proper location on the vertical side edge of the door.

[00012] It is an object of the present invention to provide a jig for guiding the cutting of a face borehole through a vertically oriented hinged door from the first face to the second face of the door to permit installation of door handles, and an edge borehole and a latch plate mortise in a vertically oriented hinged door to permit installation of a door latch assembly at the vertical side edge thereof, wherein the face borehole is cut as close as possible to the center of the door between the two faces of the door, and the edge borehole is cut and the latch plate mortise is routered as close as possible to the center of the door on the vertical side edge of the door.
Date Regue/Date Received 2022-09-22

[00013] It is an object of the present invention to provide a jig for guiding the cutting of a face borehole through a vertically oriented hinged door from the first face to the second face of the door to permit installation of door handles, and an edge borehole and a latch plate mortise in a vertically oriented hinged door to permit installation of a door latch assembly at the vertical side edge thereof, wherein the face borehole, the edge borehole and the latch plate mortise are positioned as close as possible to the correct elevational height such that the door handles and the latch of the door latch assembly are installed on the door properly aligns with the co-operating opening in the strike plate that is secured to the door frame.

[00014] It is an object of the present invention to provide a jig for guiding the cutting of a face borehole through a vertically oriented hinged door from the first face to the second face of the door to permit installation of door handles, and an edge borehole and a latch plate mortise in a vertically oriented hinged door to permit installation of a door latch assembly at the vertical side edge thereof, wherein the jig is inexpensive to manufacture.

[00015] It is an object of the present invention to provide a jig for guiding the cutting of a face borehole through a vertically oriented hinged door from the first face to the second face of the door to permit installation of door handles, and an edge borehole and a latch plate mortise in a vertically oriented hinged door to permit installation of a door latch assembly at the vertical side edge thereof, wherein the jig is robust.

[00016] It is an object of the present invention to provide a jig for guiding the cutting of a face borehole through a vertically oriented hinged door from the first face to the second face Date Regue/Date Received 2022-09-22 of the door to permit installation of door handles, and an edge borehole and a latch plate mortise in a vertically oriented hinged door to permit installation of a door latch assembly at the vertical side edge thereof, wherein the jig is easy to use.

[00017]
It is an object of the present invention to provide a jig for guiding the cutting of a face borehole through a vertically oriented hinged door from the first face to the second face of the door to permit installation of door handles, and an edge borehole and a latch plate mortise in a vertically oriented hinged door to permit installation of a door latch assembly at the vertical side edge thereof, wherein the jig helps produce excellent quality results.

[00018]
It is an object of the present invention to provide a jig for guiding the cutting of a face borehole through a vertically oriented hinged door from the first face to the second face of the door to permit installation of door handles, and an edge borehole and a latch plate mortise in a vertically oriented hinged door to permit installation of a door latch assembly at the vertical side edge thereof, wherein the jig is has replaceable removable and replaceable wear parts SUMMARY OF THE INVENTION

[00019]
In accordance with one aspect of the present invention there is disclosed a novel jig for use in configuring a door for receiving a door latch assembly and door handles.
The jig comprises a first side member for secure engagement with the first face of the door.

Date Regue/Date Received 2022-09-22 The first side member presents a face borehole cutting guide surface for guiding a hole saw for cutting a face borehole into the door at the first face of the door. A
second side member is for secure engagement with the second face of the door. The first side member and the second side member are interconnected in spaced relation each from the other by movable connectors so as to define a door-receiving channel therebetween. An edge borehole cutting guide is supported by at least one of the first side member and the second side member to thereby accurately position the edge borehole cutting guide at the side edge of the door, for guiding a hole saw to accurately cut an edge borehole in the edge of the door. A latch plate mortise cutting guide is supported by at least one of the first side member and the second side member to thereby accurately position the latch plate mortise cutting guide at the side edge of the door, for guiding a router to accurately cut a latch plate mortise in the edge of the door.

[00020] In accordance with one aspect of the present invention there is disclosed a novel jig for use in configuring a door for receiving a door latch assembly and door handles.
The jig comprises a first side member for secure engagement with the first face of the door and a second side member for secure engagement with the second face of the door.
The first side member and the second side member are interconnected in spaced relation each from the other by movable connectors so as to define a door-receiving channel therebetween. A first fine-adjustment mechanism is operatively mounted on the first side member and a second fine-adjustment mechanism is operatively mounted on the second side member, for adjusting the orientation of the various parts of the jig such that the jig is securely mounted onto on the door.

Date Recue/Date Received 2022-09-22

[00021]
In accordance with one aspect of the present invention there is disclosed a novel jig for use in configuring a door for receiving a door latch assembly and door handles.
The jig comprises a "U"-shaped main body defining a door-receiving channel.
The "U"-shaped main body presents a face borehole cutting guide surface, an edge borehole cutting guide surface, and a latch plate mortise cutting guide surface. The edge borehole cutting guide surface is disposed on an edge borehole cutting guide that is positionable in removable and replaceable relation as part of the jig.

[00022]
In accordance with another aspect of the present invention there is disclosed a novel method of configuring a door for receiving a door latch assembly and door handles. The method comprises the steps of mounting a jig onto the door at the vertical side edge thereof with the jig being secured to the first face and the second face of the door;
cutting a face borehole in the door from the first face to the second face of the door, as guided by the jig;
cutting an edge borehole in the door at the edge of the door, as guided by the jig; cutting a latch plate mortise in the door at the edge of the door, as guided by the jig;
and removing the jig from the door.
BRIEF DESCRIPTION OF THE DRAWINGS

[00023]
The novel features which are believed to be characteristic of the present invention, as to its structure, organization, use and method of operation, together with further objectives and advantages thereof, will be better understood from the following drawings in Date Recue/Date Received 2022-09-22 which an illustrated embodiment of the invention will now be illustrated by way of example. It is expressly understood, however, that the drawings are for the purpose of illustration and description only, and are not intended as a definition of the limits of the invention. In the accompanying drawings:

[00024] Figure 1 is a first perspective view of an illustrated embodiment of the jig for use in configuring a door according to the present invention, in place on a door;

[00025] Figure 2 is a second perspective view of the illustrated embodiment of the jig of Figure 1, in place on a door;

[00026] Figure 3 is a top view of the illustrated embodiment of the jig of Figure 1, in place on a door;

[00027] Figure 4 is a side view of the illustrated embodiment of the jig of Figure 1, in place on a door;

[00028] Figure 5 is a first perspective view of the illustrated embodiment of the jig of Figure 1;

[00029] Figure 6 is a second perspective view of the illustrated embodiment of the jig of Figure 1;

[00030] Figure 7 is a first exploded perspective view of the illustrated embodiment of the jig of Figure 1;
Date Regue/Date Received 2022-09-22

[00031] Figure 8 is a second exploded perspective view of the illustrated embodiment of the jig of Figure 1;

[00032] Figure 9 is a front elevational view of the illustrated embodiment of the jig of Figure 1;

[00033] Figure 10 is a rear elevational view of the illustrated embodiment of the jig of Figure 1;

[00034] Figure 11 is a top view of the illustrated embodiment of the jig of Figure 1;

[00035] Figure 12 is a bottom view of the illustrated embodiment of the jig of Figure 1;

[00036] Figure 13 is a first side view of the illustrated embodiment of the jig of Figure 1;

[00037] Figure 14 is a second side view of the illustrated embodiment of the jig of Figure 1;

[00038] Figure 15 is a first perspective view of the first side block of the illustrated embodiment of the jig of Figure 1;

[00039] Figure 16 is a second perspective view of the first side block of the illustrated embodiment of the jig of Figure 1;

[00040] Figure 17 is a front view of the first side block of the illustrated embodiment of the jig of Figure 1;

Date Regue/Date Received 2022-09-22

[00041] Figure 18 is a rear view of the first side block of the illustrated embodiment of the jig of Figure 1;

[00042] Figure 19 is a first perspective view of the second side block of the illustrated embodiment of the jig of Figure 1;

[00043] Figure 20 is a second perspective view of the second side block of the illustrated embodiment of the jig of Figure 1;

[00044] Figure 21 is a front view of the second side block of the illustrated embodiment of the jig of Figure 1;

[00045] Figure 22 is a rear view of the second side block of the illustrated embodiment of the jig of Figure 1;

[00046] Figure 23 is a perspective view of the interconnecting plate of the illustrated embodiment of the jig of Figure 1;

[00047] Figure 24 is a front view of the interconnecting plate of the illustrated embodiment of the jig of Figure 1;

[00048] Figure 25 is a perspective view of the borehole template of the illustrated embodiment of the jig of Figure 1;

[00049] Figure 26 is a front view of the borehole template of the illustrated embodiment of the jig of Figure 1;

Date Regue/Date Received 2022-09-22

[00050] Figure 27 is a perspective view of the flanged sleeve bearing of the illustrated embodiment of the jig of Figure 1;

[00051] Figure 28 is a perspective view of the rubber bumper of the illustrated embodiment of the jig of Figure 1;

[00052] Figure 29 is a perspective view of the tapping insert of the illustrated embodiment of the jig of Figure 1;

[00053] Figures 30A and 30B are perspective views of the hole saw guide insert of the illustrated embodiment of the jig of Figure 1;

[00054] Figure 31 is a first cut-away perspective view of the illustrated embodiment of the jig of Figure 1;

[00055] Figure 32 is a second cut-away perspective view of the illustrated embodiment of the jig of Figure 1;

[00056] Figure 33 is a front view of the illustrated embodiment of the jig of Figure 1;

[00057] Figure 34 is a rear view of the illustrated embodiment of the jig of Figure 1;

[00058] Figure 35 is a first side view of the illustrated embodiment of the jig of Figure 1;

[00059] Figure 36 is a second side view of the illustrated embodiment of the jig of Figure 1;

[00060] Figure 37 is a top view of the illustrated embodiment of the jig of Figure 1;

Date Regue/Date Received 2022-09-22

[00061] Figure 38 is a bottom view of the illustrated embodiment of the jig of Figure 1;

[00062] Figure 39 is a front view of the illustrated embodiment of the jig of Figure 1, with the borehole template removed; 1;

[00063] Figure 40 is a front view of the illustrated embodiment of the jig of Figure 1, with the edge borehole cutting guide removed;

[00064] Figure 41 is a perspective view of the illustrated embodiment of the jig of Figure 1, with the borehole template removed and the jig mounted on a door;

[00065] Figure 42 is an elevational view of the illustrated embodiment of the jig of Figure 1, with the borehole template removed and the jig mounted on a door, and showing the latch plate mortise having been cut;

[00066] Figure 43 is a cross-sectional elevational view of the illustrated embodiment of the jig of Figure 1;

[00067] Figure 44A is a top plan view of the illustrated embodiment of the jig of Figure 1 about to be mounted on a door;

[00068] Figure 44B is a top plan view of the illustrated embodiment of the jig of Figure 1 mounted on a door and the face borehole being cut;

[00069] Figure 44C is a top plan view of the illustrated embodiment of the jig of Figure 1 mounted on a door and the latch plate mortise being cut;

Date Regue/Date Received 2022-09-22

[00070] Figure 44D is a top plan view of the illustrated embodiment of the jig of Figure 1 mounted on a door and the edge borehole being cut; and,

[00071] Figure 44E is a top plan view of the illustrated embodiment of the jig of Figure 1 being removed from a door.
LIST OF COMPONENTS AND REFERENCE NUMERALS
100 jig 101 "U"-shaped main body 102 door 102a first face 102b second face 102c face borehole 102e edge 102f edge borehole 102m latch plate mortise 104 door latch assembly 106 door handles 107 small hole saw 108 door-receiving channel 109 finishing router Date Regue/Date Received 2022-09-22 109b router blade 110 first side member 111a inner face 111b outer face 112a first side edge 112b second side edge 113a first end edge 113b second end edge 114 reduced shoulder portion 115a aperture 115b aperture 115c aperture 116 central aperture 117 shallow rectangularly shaped central recess 117f threaded fasteners 117i tapping insert 118 face borehole cutting guide surface 119 rubber bumpers 120 second side member 121a inner face 121b outer face 122a first side edge 122b second side edge Date Recue/Date Received 2022-09-22 122c recessed portion 123a first end edge 123b second end edge 124 reduced shoulder portion 125a aperture 125b aperture 125c aperture 129 rubber bumpers 130 edge borehole cutting guide 130a generally rectangular main body 130c rounded corners 131a inner face 131b outer face 132a first side edge 132b second side edge 133a first end edge 133b second end edge 134 insert portion 135 central throughpassage 135a edge borehole cutting guide surface 136a first slot 136b second slot 137a threaded fasteners Date Recue/Date Received 2022-09-22 138a cooperating apertures 140 latch plate mortise cutting guide 140a main body 141a inner face 141b outer face 142a first side edge 142b second side edge 143a first end edge 143b second end edge 144 central rectangular opening 145 mortise cutting guide surface 146 internally threaded tapping inserts 146a first aperture 146b second aperture 147a first aperture 147b second aperture 148a first flanged sleeve bearing 148b second flanged sleeve bearing 149 generally rectangular recess 150a first "V"-shaped centering slot 150b second "V"-shaped centering slot 151a first elongate throughpassage 151b second elongate throughpassage Date Recue/Date Received 2022-09-22 160 hole saw guide insert 161a first side edge 161b second side edge 162a first flanged sleeve bearing 162b second flanged sleeve bearing 164a aperture 164b aperture 170a first fine-adjustment mechanism 170b second fine-adjustment mechanism 171a first fine adjustment screw 171b second fine adjustment screw 172a first internally threaded tapping insert 172b first internally threaded tapping insert 180a first movable connector (elongate threaded connector) 180b second movable connector (elongate threaded connector) 181a first manually graspable head portion 181b second manually graspable head portion 182a tapping insert 182b tapping insert Date Recue/Date Received 2022-09-22 DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

[00072] Reference will now be made to Figures 1 through 44E, which show an illustrated embodiment of the jig according to the present invention, as indicated by the general reference numeral 100. The jig 100 for use in configuring a door 102 for receiving a door latch assembly 104 and door handles 106. Figures 1 through 4 show the jig 100 in place on a door 102.
Figures 1 and 2 show an example door having more than one face borehole, more than one edge borehole, and more than one latch plate mortise

[00073] In brief, the jig 100 comprises a first side member 110, a second side member 120, an edge borehole cutting guide 130, and latch plate mortise cutting guide 140, and a rectangularly shaped hole saw guide insert 160.

[00074] More specifically, the jig 100 comprises a first side member 110 for secure engagement with the first face 102a of the door 102. In the illustrated embodiment, the first side member 110 comprises a first side block extending between an inner face 111a, an outer face 111b, a first side edge 112a, a second side edge 112b, a first end edge 113a, and a second end edge 113b. A reduced shoulder portion 114 located at the junction of the inner face 111a and first side edge 112a is for receiving the first side edge 142a of the latch plate mortise cutting guide 140 therein. There are three apertures 115a, 115b, 115c in the first side member 110 at the reduced shoulder portion 114. Aperture 115a is for receiving a first movable connector 180a therethrough, aperture 115b is for receiving a second movable Date Recue/Date Received 2022-09-22 connector 180b therethrough, and aperture 115c is for receiving a first fine adjustment screw 171a therethrough, as will be discussed in greater detail subsequently.

[00075] A central aperture 116 is for receiving the circular blade 107a of a hole saw 107 therethrough, to thereby permit the cutting of a face borehole 102c in the door 102 from the first face 102a of the door 102 to the second face of the door 102.

[00076] There is also a shallow rectangularly shaped central recess 117 for receiving and retaining the rectangularly-shaped co-operating hole saw guide insert 160 therein. The guide insert 160 comprises a rectangular block that is received and retained in removable relation by the first side member 110. More specifically, the hole saw guide insert 160 is positionable in removable and replaceable relation within the shallow rectangularly shaped central recess 117 in the first side member 110. The rectangular hole saw guide insert 160 is retained snugly in place by a threaded fasteners 117f each engaged within an internally threaded tapping insert 117i the first side member 110. A first flanged sleeve bearing 162a is disposed within a co-operating aperture 164a in the first side edge 161a of the hole saw guide insert 160. Similarly, a second flanged sleeve bearing 162b is disposed within a co-operting aperture 164b in the second side edge 162a of the hole saw guide insert 160. The threaded fasteners 117f abut against the first flanged sleeve bearing 162a and the second flanged sleeve bearing 162b to retain the hole saw guide insert 160 in place. The first flanged sleeve bearing 162a and the second flanged sleeve bearing 162b are made from a suitable hard plastic or metal material and are each for receiving thereagainst the end portion of a co-opeating threaded fastener 117f.

Date Recue/Date Received 2022-09-22

[00077] The first side member 110 presents a circular face borehole cutting guide surface 118 for guiding a hole saw 107 as it cuts a face borehole 102c into the door 102 at the first face 102a of the door 102. In the illustrated embodiment, the circular face borehole cutting guide surface 118 is formed on the hole saw guide insert 160. The hole saw guide insert 160, and more specifically the face borehole cutting guide surface 118, is for assisting in accurately cutting a face borehole 102c in the door 102.

[00078] The circular face borehole cutting guide surface 118 is disposed in offset relation to the center of the rectangularly shaped hole saw guide insert 160.
Accordingly, when the rectangularly shaped hole saw guide insert 160 is oriented as shown in the figures, the center of the circular face borehole cutting guide surface 118 is at a first backset distance (2 3/8 inches) from the first side edge 112a of the first side member 110. When the rectangularly shaped hole saw guide insert 160 is removed, rotated one-hundred eighty degrees, and replaced into the cooperating shallow rectangularly shaped central recess 117, the center of the circular face borehole cutting guide surface 118 is at a second backset distance (2 3/4 inches) from the first side edge 112a of the first side member 110.
Accordingly, the face borehole 102c may be accurately cut with a hole saw 107 so as to have it's center at the first backset distance (2 3/8 inches) from the first side edge 112a of the first side member 110 or at the second backset distance (2 3/4 inches) from the first side edge 112a of the first side member 110. The central aperture 116 is slightly oblong to accommodate the face borehole cutting guide surface 118.

Date Recue/Date Received 2022-09-22

[00079] In use, in order to cut the face borehole 102c through the door 102 accurately at the proper location, an appropriately sized hole saw 107 is positioned at the face borehole cutting guide surface 118 so as to be aligned therewith, and face board wall is cut into the door 102.

[00080] There is also a second side member 120 for secure engagement with the second face of the door 102. In the illustrated embodiment, the second side member 120 comprises a second side block extending between an inner face 121a, an outer face 121b, a first side edge 122a, a second side edge 122b, a first end edge 123a, a second end edge 123b.

[00081] A reduced shoulder portion 124 located at the junction of the inner face 121a and first side edge 122a is for receiving the second side edge 142b of the latch plate mortise cutting guide 140 therein. There are three apertures 125a, 125b, 125c in the second side member 120 at the reduced shoulder portion 124. Aperture 125a is for receiving a first movable connector 180a therethrough, aperture 125b is for receiving a second movable connector 180b therethrough, and aperture 125c is for receiving a second fine adjustment screw 171b therethrough, as will be discussed in greater detail subsequently.

[00082] As can be readily seen, the second side block 120 is smaller than the first side block 110 since it does not need to carry the hole saw guide insert 160.
However, there is a recessed portion 122c in the second side edge 122b to accommodate a hole saw 107 as it cuts through the door 102.

Date Recue/Date Received 2022-09-22

[00083] The first side member 110 and the second side member 120 are interconnected in spaced relation each from the other by the first and second movable connectors 180a, 180b so as to define a door-receiving channel 108 therebetween. The first side member 110 has rubber bumpers 119 on the inner face 111a thereof for precluding damage to the first face 102a of the door 102, and similarly the second side member 120 has rubber bumpers 129 on the inner face 121a thereof for precluding damage to the second face 102b of the door 102.

[00084] In the illustrated embodiment of the present invention, the first movable connector 180a comprises a first elongate threaded connector 180a and the second movable connector 180b comprises a second elongate threaded connector 180b. The first elongate threaded connector 180a has a first manually graspable head portion 181a secured thereto for rotation therewith. The first manually graspable head portion 181a extends outwardly from the first side member 110 for manual turning of the first elongate threaded connector 180a.
Similarly, the second elongate threaded connector 180b has a second manually graspable head portion 181b secured thereto for rotation therewith. The second manually graspable head portion 181b extends outwardly from the second side member 120 for manual turning of the second elongate threaded connector 180b.

[00085] A latch plate mortise cutting guide 140 comprises a rectangular main body 140a extending between an inner face 141a, an outer face 141b, a first side edge 142a, a second side edge 142b, a top edge 143a, and a bottom edge 143b. The inner face 141a is sloped at a three degree (30) angle with respect to the outer face 141b, at a ninety-three degree (930) angle with respect to the first side edge 142a, and an eighty-seven degree (87 ) angle with Date Recue/Date Received 2022-09-22 respect to the second side edge 142b, in order to accommodate the three degree (30) slope of the outer edge of many doors.

[00086] A central rectangular opening 144 defines a mortise cutting guide surface 145 that is for guiding a router 109 to accurately cut a latch plate mortise 102m in the edge 102e of the door 102. The router blade 109b of the router 109 does not contact the latch plate mortise cutting guide surface 145. The only contact with the mortise cutting guide surface 145 is by the outer circumferential surface of the bearing that carries the router blade 109b. In this manner, the latch plate mortise cutting guide 140 does not get damaged by the router blade 109b.

[00087] Two internally threaded tapping inserts 146 are threadibly retained one in each of a first aperture 146a and a second aperture 146b located at the opposite ends of the central rectangular opening 144. These two internally threaded tapping inserts 146 receive threaded fasteners 137a that secure the edge borehole cutting guide 130 onto the latch plate mortise cutting guide 140.

[00088] There is a first aperture 147a located in the first side edge 142a of the main body portion 140a and a second aperture 147b located in the second side edge 142b of the main body portion 140a. The first aperture 147a has a first flanged sleeve bearing 148a therein and the second aperture 147b has a second flanged sleeve bearing 148b therein. The first flanged sleeve bearing 148a and the second flanged sleeve bearing 148b are made from a suitable hard plastic or metal material and are each for receiving thereagainst the end portion of a first Date Recue/Date Received 2022-09-22 fine adjustment screw 171a and a second fine adjustment screw 171b, respectively, as will be discussed in greater detail subsequently.

[00089] There is also a first "V"-shaped centering slot 150a located in the first end edge 143a of the main body 140b and a second "V"-shaped centering slot 150b located in the second end edge 143b of the main body 140b. In use, the first "V"-shaped centering slot 150a and the second "V"-shaped centering slot 150b are used to accurately center the latch plate mortise cutting guide 140 during mounting of the jig 100 on to a door 102. Typically, a centerline is drawn on the edge of the door 102 and the vertices of each of the first "V"-shaped centering slot 150a and the second "V"-shaped centering slot 150b are aligned with the drawn centerline.

[00090] The latch plate mortise cutting guide 140 also has a first elongate throughpassage 151a extending between the first side edge 142a and the second side edge 142b, and a second elongate throughpassage 151b extending between the first side edge 142a and the second side edge 142b. The first movable connector (elongate threaded connector) 180a extends through the first elongate throughpassage 151a and the second movable connector (elongate threaded connector) 180b extends through the second elongate throughpassage 151b.

[00091] The latch plate mortise cutting guide 140 supported by at least one of the first side member 110 and the second side member 120 to thereby accurately position the latch plate mortise cutting guide 140 at the side edge of the door 102, for guiding a router to accurately cut a latch plate mortise in the edge of the door 102. In the illustrated embodiment, Date Recue/Date Received 2022-09-22 the latch plate mortise cutting guide 140 is supported by both of the first side member 110 and the second side member 120 via the first movable connector (elongate threaded connector) 180a and the second movable connector (elongate threaded connector) 180b. More specifically, the latch plate mortise cutting guide 140 is disposed between the first side member 110 and the second side member 120.

[00092] The edge borehole cutting guide 130 comprises a generally rectangular main body 130a with rounded corners 130c and extends between an inner face 131a, an outer face 131b, a first side edge 132a, a second side edge 132b, a first end edge 133a, a second end edge 133b. An insert portion 134 extends outwardly from the inner face 131a of the main body 130a and has a central throughpassage 135 therein, as defined by an edge borehole cutting guide surface 135a, for receiving a small hole saw 107 therethrough. There is a first slot 136a in the insert portion 134 adjacent the first side edge 132a of the edge borehole cutting guide 130 and a second slot 136b in the insert portion 134 adjacent the second side edge 132b of the edge borehole cutting guide 130. The first slot 136a and the second slot 136b permit marking of the center of the edge borehole 102f.

[00093] The edge borehole cutting guide 130 is supported by at least one of the first side member 110 and the second side member 120, to thereby accurately position the edge borehole cutting guide 130 at the side edge of the door 102, for guiding a hole saw 107 to accurately cut the edge borehole 102f in the edge 102e of the door 102. More specifically, the edge borehole cutting guide 130 is mounted in removable and replaceable relation on the latch plate mortise cutting guide 140, such that the generally rectangular main body 130a seats Date Recue/Date Received 2022-09-22 within a co-operatingly shaped generally rectangular recess 149 in the second face 142b of the latch plate mortise cutting guide 140. The insert portion 134 fits within the central rectangular opening 144 of the latch plate mortise cutting guide 140. The edge borehole cutting guide 130 and therefore the insert portion 134 are retained in place by a pair of threaded fasteners 137a that extend through cooperating apertures 138a in the generally rectangular main body 130a of the edge borehole cutting guide 130. The threaded fasteners 137a are securely engaged in co-operating internally threaded tapping inserts 146 that are securely retained one each in a first aperture 146a and a second aperture 146b the latch plate mortise cutting guide 140.

[00094] The first elongate threaded connector 180a is rotatably engaged in the first side member 110 and is threadably engaged in the second side member 120. More specifically, the first elongate threaded connector 180a extends through aperture 115a in the first side member 110 and is threadably engaged in the internally threaded tapping insert 146 that is securely seated in aperture 125a in the second side member 120. Similarly, the second elongate threaded connector 180b is rotatably engaged in the second side member 120 and threadably engaged in the first side member 110. More specifically, the second elongate threaded connector 180b extends through aperture 125b in the second side member 120 and is threadably engaged in the internally threaded tapping insert 146 that is securely seated in aperture 115b in the first side member 120. Further, the first elongate threaded connector 180a extends through the first elongate throughpassage 151a in the latch plate mortise cutting guide 140 and the second elongate threaded connector 180b extends through a second elongate throughpassage 151b in the latch plate mortise cutting guide 140.

Date Recue/Date Received 2022-09-22

[00095] In use, with the jig 100 according to the present invention, in order to form the edge borehole 102f in the edge of the door 102, the edge borehole cutting guide 130 is put in place in the latch plate mortise cutting guide 140, and a hole saw 107 is inserted into the central throughpassage 135. The borehole cutting guide surface 135a, which defines the perimeter of the central throughpassage 135, accurately guides the hole saw 107.
Typically, this operation is done first before forming the latch plate mortise 102m in the edge of the door 102 in order to permit sawdust to be properly dispersed.

[00096] In order to form the latch plate mortise 102m in the edge of the door 102, the edge borehole cutting guide 130 is removed from the latch plate mortise cutting guide 140.
The router blade 109 of a finishing router 109 is then inserted into the central rectangular opening 144 of the latch plate mortise cutting guide 140 and is moved around the area of the central rectangular opening 144, as bounded by the mortise cutting guide surface 145.

[00097] In this manner, the face borehole 102c, the edge borehole 102f, and the latch plate mortise 102m and can each be formed with the assistance of the jig 100 according to the present invention, and without removing and replacing the jig 100 during the overall operation of forming latch plate mortise and the edge borehole, which is unknown in the prior art.

[00098] The jig 100 further comprises a first fine-adjustment mechanism 170a operatively mounted on the first side member 110 and a second fine-adjustment mechanism 170b operatively mounted on the second side member 120. As illustrated, the first fine-adjustment Date Regue/Date Received 2022-09-22 mechanism 170a comprises a first fine-adjustment screw 171a that is threadably engaged in a co-operating first internally threaded tapping insert 172a that is securely retained within the aperture 115c in the first side member 110 so as to extend through the aperture 115c to contact the first flanged sleeve bearing 148a in the latch plate mortise cutting guide 140. Similarly, the second fine-adjustment mechanism 170b comprises a second fine-adjustment screw 171b that is threadably engaged in a co-operating second internally threaded tapping insert 172b that is securely retained within the aperture 125c in the second side member 120 so as to extend through the second threaded throughpassage 173b to contact the second flanged sleeve bearing 148b in the latch plate mortise cutting guide 140.

[00099] The first fine-adjustment mechanism 170a and the second fine-adjustment mechanism 170b are generally centrally disposed between the first movable connector (elongate threaded connector) 180a and the second movable connector (elongate threaded connector) 180b.

[000100] In use, the first elongate threaded connector and the second elongate threaded connector are used to mount the jig 100 onto a door 102, with the first side member 110 against the first face 102a of the door 102 and the second side member 120 against the second face of the door 102. Subsequently to the jig 100 being mounted onto the door 102, the first fine adjustment mechanism and the second fine adjustment mechanism are used to adjust the orientation of the various parts of the jig 100, so that the jig 100 is securely mounted onto the door 102. It has been found that using the first fine-adjustment mechanism 170a and the second fine-adjustment mechanism 170b in conjunction with the first movable connector Date Recue/Date Received 2022-09-22 (elongate threaded connector) 180a and the second movable connector (elongate threaded connector) 180b allows for proper adjustment for the secure attachment of the jig 110 onto a door 102.

[000101] In another aspect, the present invention comprises a jig 100 for use in configuring a door 102 for receiving a door latch assembly 104 and door handles 106. The jig 100 comprises a "U"-shaped main body 101 defining the door-receiving channel 108.
The "U"-shaped main body 101 also presents the face borehole cutting guide surface 118, the edge borehole cutting guide surface 135a, and the latch plate mortise cutting guide surface 145.
The edge borehole cutting guide surface 135a is disposed on the edge borehole cutting guide 130 that is positionable in removable and replaceable relation as part of the jig. Further, the latch plate mortise cutting guide surface 145 is disposed on a latch plate mortise cutting guide 140. Further, the edge borehole cutting guide 130 is mounted in removable and replaceable relation on the latch plate mortise cutting guide 140.

[000102] In another aspect, the present invention comprises a method of configuring a door 102. The method comprises the following steps. It should be noted that step (1) should be done first, steps (2), (3) and (4) are perhaps done best in that order but can be done in any order after step (1) and before step (5), and step (5) is best done last.
(1) mounting a jig 100 on the door 102 at the vertical side edge 102e thereof with the jig 100 being secured to the first face 102a and the second face of the door 102; (Fig 44A) Date Recue/Date Received 2022-09-22 (2) cutting a face borehole 102c in the door 102 from the first face 102a to the second face of the door 102, as guided by the jig 100; (Fig 44B) (3) cutting an edge borehole 102f in the door 102 at the edge of the door 102, as guided by the jig 100; (Fig 44C) (4) cutting a latch plate mortise 102m in the door 102 at the edge of the door 102, as guided by the jig 100; (Fig 44D) and;
(5) removing the jig 100 from the door 102. (Fig 44E)

[000103] Other variations are within the spirit of the present invention.
Thus, while the invention is susceptible to various modifications and alternative constructions without departing from the spirit of the inventions disclosed and claimed, only a limited number of embodiments or variations thereof have been illustrated or otherwise disclosed herein by way of non-limiting example. It should be understood, however, that there is no intention to limit the invention to the specific form or forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention, as defined in the appended claims broadly construed.

[000104] The use of the terms "a" and "an" and "the" and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly Date Regue/Date Received 2022-09-22 contradicted by context. The terms "comprising," "having," "including," and "containing" are to be construed as open-ended terms (i.e., meaning "including, but not limited to,") unless otherwise noted. The term "connected" is to be construed as partly or wholly contained within, attached to, or joined together, even if there is something intervening.
Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. The use of any and all examples, or exemplary language (e.g., "such as", or, "for example") provided herein, is intended merely to better illuminate embodiments of the invention and does not pose a limitation on the scope of the invention unless otherwise claimed.
No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[000105] Currently preferred embodiments of this invention are described herein.
Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

Date Regue/Date Received 2022-09-22

Claims (29)

CLAIMS:

1.
A jig for use in configuring a door for receiving a door latch assembly and door handles, said jig comprising:
a first side member for secure engagement with the first face of said door;
wherein said first side member presents a face borehole cutting guide surface for guiding a hole saw for cutting a face borehole into said door at the first face of said door;
a second side member for secure engagement with the second face of said door;
wherein said first side member and said second side member are interconnected in spaced relation each from the other by movable connectors so as to define a door-receiving channel therebetween;
an edge borehole cutting guide supported by at least one of said first side member and said second side member to thereby accurately position said edge borehole cutting guide at the side edge of said door, for guiding a hole saw to accurately cut an edge borehole in the edge of said door; and, a latch plate mortise cutting guide supported by at least one of said first side member and said second side member to thereby accurately position said latch plate mortise cutting guide at the side edge of said door, for guiding a router to accurately cut a latch plate mortise in the edge of said door.

2. A jig for use in configuring a door according to claim 1, wherein said first side member comprises a first side block.

3. A jig for use in configuring a door according to claim 2, wherein said second side member comprises a second side block.

4. A jig for use in configuring a door according to claim 3, wherein said first side block is bigger than the second side block.

5. A jig for use in configuring a door according to claim 1, wherein said face borehole cutting guide surface defines an opening in said first side member.

6. A jig for use in configuring a door according to claim 5, wherein said face borehole cutting guide surface defines a circular aperture in said first side member.

7. A jig for use in configuring a door according to claim 6, further comprising a guide insert positionable in removable and replaceable relation in said first side member

8. A jig for use in configuring a door according to claim 7, wherein said face borehole cutting guide surface is disposed in said guide insert.

9. A jig for use in configuring a door according to claim 8, wherein said guide insert comprises a square block and said circular face borehole cutting guide surface is disposed in offset relation to the center of said square.

10. A jig for use in configuring a door according to claim 1, wherein said first side member and said second side member are interconnected in spaced relation each from the other by threaded fasteners.

11. A jig for use in configuring a door according to claim 10, wherein said threaded fasteners comprise a first threaded fastener and a second threaded fastener.

12. A jig for use in configuring a door according to claim 11, wherein said first threaded fastener has a first manually graspable head portion secured thereto for rotation therewith and extending outwardly from said first side member for manual turning of said first threaded fastener and said second threaded fastener has a second manually graspable head portion secured thereto for rotation therewith and extending outwardly from said second side member for manual turning of said second threaded fastener.

13. A jig for use in configuring a door according to claim 12, wherein said first threaded fastener is rotatably engaged in said first side member and threadably engaged in said second side member, and said second threaded fastener is rotatably engaged in said second side member and threadably engaged in said first side member.

14. A jig for use in configuring a door according to claim 13, wherein said first threaded fastener extends through a first throughpassage in said latch plate mortise cutting guide and said second threaded fastener extends through a second throughpassage in said latch plate mortise cutting guide.

15. A jig for use in configuring a door according to claim 1, wherein said latch plate mortise cutting guide is disposed between said first side member and said second side member.

16. A jig for use in configuring a door according to claim 1, wherein said latch plate mortise cutting guide includes a mortise cutting guide surface.

17. A jig for use in configuring a door according to claim 16, wherein said latch plate mortise cutting guide has a central rectangular opening that defines said mortise cutting guide surface.

18. A jig for use in configuring a door according to claim 15, wherein said edge borehole cutting guide is mounted in removable and replaceable relation on said latch plate mortise cutting guide.

19. A jig for use in configuring a door according to claim 1, further comprising a first fine-adjustment mechanism operatively mounted on said first side member and a second fine-adjustment mechanism operatively mounted on said second side member.

20. A jig for use in configuring a door according to claim 19, wherein said first fine-adjustment mechanism comprises a first set screw threadably engaged in a co-operating first threaded throughpassage in said first side member so as to extend through said first threaded throughpassage to contact said second side member, and a second set screw threadably engaged in a co-operating second threaded throughpassage in said second side member so as to extend through said second threaded throughpassage to contact said first side member.

21. A jig for use in configuring a door according to claim 20, wherein said first fine-adjustment mechanism is generally centrally disposed between said first threaded fastener and said second threaded fastener, and said second fine-adjustment mechanism is generally centrally disposed between said first threaded fastener and said second threaded fastener.

22. A jig for use in configuring a door for receiving a door latch assembly and door handles, said jig comprising:
a first side member for secure engagement with the first face of said door;
a second side member for secure engagement with the second face of said door;
wherein said first side member and said second side member are interconnected in spaced relation each from the other by movable connectors so as to define a door-receiving channel therebetween; and, a first fine-adjustment mechanism operatively mounted on said first side member and a second fine-adjustment mechanism operatively mounted on said second side member, for adjusting the orientation of the various parts of the jig such that the jig is securely mounted onto on the door.

23. A jig for use in configuring a door according to claim 22, wherein said first fine-adjustment mechanism comprises a first set screw threadably engaged in a co-operating first threaded throughpassage in said first side member so as to extend through said first threaded throughpassage to contact said second side member, and a second set screw threadably engaged in a co-operating second threaded throughpassage in said second side member so as to extend through said second threaded throughpassage to contact said first side member.

24. A jig for use in configuring a door according to claim 22, wherein said movable connectors comprise a first movable connector and a second movable connector, and said first fine-adjustment mechanism and said second are each generally centrally disposed between said first movable connector and said second movable connector.

25. A jig for use in configuring a door for receiving a door latch assembly and door handles, said jig comprising:
a "U"-shaped main body defining a door-receiving channel;

wherein said "U"-shaped main body presents a face borehole cutting guide surface, an edge borehole cutting guide surface, and a latch plate mortise cutting guide surface;
wherein said edge borehole cutting guide surface is disposed on an edge borehole cutting guide that is positionable in removable and replaceable relation as part of said jig.

26. A jig for use in configuring a door according to claim 25, wherein said latch plate mortise cutting guide surface is disposed on a latch plate mortise cutting guide, and said edge borehole cutting guide is mounted in removable and replaceable relation on said latch plate mortise cutting guide.

27. A method of configuring a door for receiving a door latch assembly and door handles comprises the steps of:
(1) mounting a jig onto the door at the vertical side edge thereof with the jig being secured to the first face and the second face of said door;
(2) cutting a face borehole in said door from the first face to the second face of said door, as guided by said jig;
(3) cutting an edge borehole in said door at the edge of said door, as guided by said jig;

(4) cutting a latch plate mortise in said door at the edge of said door, as guided by said jig; and;
(5) removing said jig from the door.

28. A method of configuring a door for receiving a door latch assembly and door handles according to claim 27, further comprising the step of:
after step (3) and before step (4), removing an edge borehole cutting guide.

29. A method of configuring a door for receiving a door latch assembly and door handles according to claim 27, wherein:
the step of mounting a jig onto the door at the vertical side edge thereof with the jig being secured to the first face and the second face of said door further comprises the step of using a first fine-adjustment mechanism and a second fine-adjustment mechanism to adjust the orientation of the various parts of the jig such that the jig is securely mounted onto on the door.