How to Drill Concealed Hinge Holes: Setback, Depth & Test Fitting

Fivalo workshop technique • Concealed hinges

Know the rim. Locate the centre. Test the depth.

The large cup hole is only part of the hinge installation. The fixing pattern, mounting plate, door thickness and overlay arrangement also have to work together. This guide explains the drilling references for compatible screw-in European concealed hinges. It does not supply universal settings for every hinge, press-in fixing or door profile.

Read the hinge drawing before setting the jig

Identify the exact hinge and matching plate first. Find the required cup diameter, boring depth, setback definition, fixing-hole pattern, screw or dowel requirements, and allowable door thickness. Hinge quantity and vertical spacing depend on door size, weight, construction and the manufacturer’s guidance. Do not choose them from the cup diameter alone.

Tools and materials

• The actual hinges, matching plates, specified fixings and current installation drawing.
• A compatible concealed-hinge boring jig and cutter, or a correctly set drill press with a suitable boring bit and depth stop; plus the required pilot bits.
• Drill, physical depth stop, suitable clamps and flat padded supports.
• Square, rule or caliper, pencil and a depth gauge suitable for the recess.
• Matching scrap with the same measured thickness and relevant material construction as the door.
• Eye protection and a hand screwdriver for controlled final fastening.

Check that the jig’s edge reference can seat on the door profile and that its guide pattern matches the chosen hinge. A nominal sheet label is not the measured thickness. Position the inside face upward for boring and keep the door supported so it cannot move or tip.

Cup setback is not the hole-centre distance

Centre distance = setback + radius = 3 + 17.5 = 20.5 mm / approximately 0.807″. The 3 mm / approximately 0.118″ example is the strip of wood between the door edge and the nearest cup rim. It is not the distance to the cutter’s centre. Confirm that your hinge drawing uses the same definition before applying the formula.

Check depth independently

For a measured 19 mm / approximately 0.748″ door and a selected hinge requiring a 13 mm / approximately 0.512″ cylindrical recess, nominal material below the flat cup floor is 6 mm / approximately 0.236″. A cutter’s centre spur may project below that floor. The test piece must confirm that the real cutter and stop leave the front face intact.

Step 1 — Mark from the hinge drawing and one door reference

1. Measure the door thickness and identify its inside face, top and hinge edge. Check the edge profile provides the flat reference your jig requires.
2. Read the cup diameter, rim setback, depth and fixing pattern from the chosen hinge drawing. Confirm compatibility with the jig and cutter.
3. Mark the hinge positions using the specified number and spacing for this door. Reference the positions from one consistent door end.
4. Calculate or verify the edge-to-centre distance separately from the rim setback. Transfer the same reference system to a matching test coupon.

Fivalo tip: Keep the hinge drawing beside the bench. A familiar cup diameter does not prove that another hinge shares its depth, screw pattern or overlay geometry.

Step 2 — Prove the stop setting on a matching test piece

1. Clamp matching scrap securely. With a handheld jig, seat its edge reference and set the cutter stop as instructed. With a drill press, establish the centre position and set the machine’s depth stop. In either case, use the required recess depth.
2. Bore the cup perpendicular to the inside face using the chosen setup. Follow the cutter’s speed and feed requirements, and stop the tool before clearing chips or checking the hole.
3. Measure the cylindrical recess at its flat floor, away from the centre-spur depression. Trial-seat the actual hinge and inspect the opposite face for damage. Adjust and repeat on sound scrap if needed.
4. After a successful test, use the proven setup on the door. For a compatible jig with matching screw guides, retain the clamped position through the cup and both pilot-hole operations before moving it. Use the specified pilot diameter and depth.

Fivalo tip: The depth-stop setting only becomes useful after a real test confirms what that cutter produces. Do not rely on a perspective image or a generic depth number.

The Fivalo Concealed Hinge Jig is designed to guide a compatible 35 mm / approximately 1.378″ cup and the two mounting-screw pilot locations from a clamped reference. Check the chosen hinge’s setback, depth and guide pattern first. Retaining the clamp position helps preserve the relationship between these drilling operations.

What the fit is telling you

Frequently asked questions

Are all concealed hinge cups the same diameter?

No. This guide’s worked example uses a 35 mm / approximately 1.378″ cup. Other hinge systems use different sizes and preparation requirements.

How far from the edge should I drill?

Use the selected hinge application’s rim setback and add half the cup diameter to locate the centre. Do not copy the example setback without checking your drawing.

Can I drill the holes without a drill press?

A compatible guided jig can support the operation with a suitable hand drill. Clamp the work securely, use the correct cutter and stop, and verify the setup on matching scrap.

Should I move the jig before drilling screw pilots?

For the compatible Fivalo cup-and-guide sequence, keep the jig clamped until the cup and both screw-guide operations are complete. A different hinge pattern needs its own approved preparation method.

Can I use this guide for press-in or dowelled hinges?

Do not substitute screw-pilot instructions for press-in or dowelled hardware. Those versions require their specified hole diameters, depths and fixing pattern.

Will correctly drilled cups guarantee even door gaps?

No. The matching mounting plates, their positions, cabinet squareness, hinge selection and final adjustments all contribute to the result.

For consistent references across a cabinet project, read our measuring and marking guide and explore more Timber Tips.