How to Cut Out a Door Hinge with a Dremel

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Nothing says fun like saving money and a do-it-yourself project. Installing a door doesn’t have to be stressful nor does it have to break the beak.

With the right materials, tools, and instructions you can be sure to walk through your new door in no time. Before diving into the steps, know that door hinges are the most important part of this process.

Hinges that aren’t tight enough, poorly measured, or inappropriately placed, can cause your door to fall due to lack of support. Who wants that?

What is a Dremel? 

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A Dremel is a fast, versatile and electrical carving tool that has a multitude of uses; with its speed and low torque control, Dremel’s allows you to saw, carve, grind, sand, and drill with precision. Because it is compact and flexible you’re allowed to get into small places (which is a huge plus). While widely used in professional industries, its’ easy-to-use nature makes this a handy tool for hobbyists, wood carving amateurs, or at-home do-it-yourself individuals such as yourself. From jewelry making to polishing objects, the possibilities are endless. 

Supply Checklist 

  • A screwdriver
  • Drill (optional)
  • Door hinges
  • Measuring tape
  • Utility knife
  • Screws
  • Dremel
  • Dustpan
  • Safety goggles
  • 650 router bit

When working with sharp tools it is important to keep safety first. Be sure to take precautions by wearing protective eye gear to prevent any wood debris from getting in your eyes. Wearing protective hand gear such as gloves are also super beneficial; make sure the gloves are thick and durable because if you accidentally brush your hand against the sharp wood or electrical drill, it’ll prevent the chance of your skin being penetrated. Consider having a friend spot you or be an assistant just in case something happens. Prevention is better than treatment. 

Also Read: Wood Carving Ideas With Dremel

How To Cut Out A Door Hinge With A Dremel

Photo: Youtube

Once you have all your tools and you’ve taken the proper safety measures you’re ready to start!

Step 1: Mark the Door

First, you must precisely mark the door. This will allow you to place the hinges in the correct place. Place the door next to it with the joint receiving side faced upwards. Now use your tape measure or a piece of tape to measure the distance between the door and mark it with your pencil. 

Also Read: Best Carpenter Pencil

Step 2: Trace the Hinges

Now that you have marked the spot of hinges, trace the actual hinge. Place the door flat on the ground, line the hinge up with the tape marking, and grab your pencil. Be sure to place your hinge on the straight edge of the door in a folded manner as it would be when you plan to open and close it. Make sure it is at its proper axis for opening and closing then trace it 1-2 times with a utility knife. Cut as close to the hinge as possible with the knife. Do it as many times as you need to see the marking. 

Step 3: Set Up Dremel

At this point, make sure your Dremel is equipped with your 650 router bit. Open the spindle and carefully attach the bit you need. If you don’t have the specific 650, a straight bit will suffice. Tighten it as tight as you can and make sure your cutting depth is correct. Adjust the cutting height to match. 

Step 4: Cut the Hinges

Now, you’re ready to put your Dremel to use. Line up your Dremel bit with the lines you traced in step 2. Slowly press down on the edges of the area. Using light pressure, keep sanding the area until the wood is removed. Expect wood debris as you do this. Next, grab the door hinge to ensure it fits perfectly. If not, gently repeat the Dremel process until it is the perfect fit for the door henge.  

Step 5: Install Hinges

This is the easy part! Now that your door hinges fit, hold the hardware in place and screw them into place. You can use a drill or screwdriver, electric is an option. 

Tip: Screw the hinge in the middle first if you don’t have any help so you won’t have to hold the hardware steady. Continue this process until you’ve secured all your hinges. Gently move the door to see if everything is secure. Be sure not to swing it too aggressively because if things are loose, your door could fall. If everything checks out, you are good to go!

Frequently Asked Questions

Can You Use a Dremel System for Door Hinges? 

Yes, with the router attachment your Dremel system can easily install door hinges. The Dremel will make it easier to mount your door hinges. 

Can you cut glass with a Dremel? 

Yes, however, it requires a different Dremel bit. Using a 545 Diamond Wheel or 663DR glass drill bit is more appropriate. You can still crack the glass with the correct drill bit so running the glass underneath water before touching it with the Dremel can be beneficial.

Can You Route with a Dremel?

Yes, adding a router attachment to your Dremel will allow you to route circles and do precise carvings.  


Cutting out a door hinge with a Dremel can be easy as long as you have the correct tools and accurate measurements. Be sure to take all safety precautions and possibly have assistance from a friend. No need to be intimidated, just follow these 5 simple steps and you’ll have a newly installed door in your home!

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