One of the worst tools I've ever owned (updated)
If you are simply looking to see whether or not I think you should buy this tool, my simple answer is "NO".
Here's the long answer:
We used to work for a very large custom millwork company, and for a long time we used the Porter-Cable template. Our boss was careless, and regularly nicked the template with the router. Over time, replacing full single hinge templates got costly, so we switched to the Bosch kit because of being able to replace smaller parts. That kit worked quite well and solved those problems.
Since then, we've left that company and started our own. Using our knowledge from the previous company, we chose the Bosch 83038 kit over the Porter-Cable.
That leads me to my need to write this review.
Upon first impression, this kit comes in a nice, sturdy box. When I took the template out, and tried to get accustomed to it, I noticed that the spacer rails did not fit into the templates. After a lot of filing, they finally slid in. I then found that if you slide them past the opening, they lock up again on the raised lettering on the template itself. After more filing, this problem was fixed.
Next thing I noticed, the top gauge assemblies. The stop tab is made of a very malleable metal, and one actually came out of the box twisted. This doesn't make for any kind of repeatability.
I went to set up my router (a Ridgid router, which I Highly recommend) to mortise. Bosch claims that this kit is fully compatible with the "competition's" template guides. While this is true, the provided router bit does not work (safely) with a Porter-Cable style template guide with a ring that screws on from the inside of the router base. In order to get the right mortise depth, the bit has to be inserted with enough of the 1/4" shaft exposed that you seriously risk bending the shaft and/or throwing the bit. If you plan on using this kit with a non-Bosch router, be prepared to use a longer bit.
Getting to actually using this template kit, I had to make wooden rails to accommodate the windows I was mortising, which isn't a huge deal. after that, I noticed that there is no depth setting for 1 1/2" thick doors, so I had to shim the template every time I used it.
The spring loaded nails are most definitely stronger that those on the Porter-Cable. The trade-off is that the larger diameter at the top makes it trickier than it should be to pull the nails out with a standard claw hammer, as the cutout in the claw won't fit around it.
I had spent about a day of mortising and hanging windows, and came to one that gave me problems. I mortised it, and when I hung it, the reveal at the top was 1/8" larger than all the rest were (with the same jig settings). I came to find out that the screw that locks the top gauge assembly had loosened and the gauge had moved. This left me having to hand mortise the hinges 1/8" higher, and do a repair to fill the lower portion of the mortise.
One of the big selling points of this template is that you can get parts for each of the templates if you nick them. I have mortised many doors now, and work at a pretty fast rate. I've never nicked a template. Just don't be careless and you'll be fine.
All that said, this kit has caused me nothing but headaches. We will be switching to the Porter-Cable kit.
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This is an addition several months later.
We now also have the Porter Cable template guide, and I use them for different purposes. I find that the Porter Cable is MUCH more adjustable and accurate. The Bosch is slightly better for 6-8 or 7-0 doors, but I don't like it for any other sizes.
We noticed a large problem with the jamb stop (provides the proper gap at the top of the door). It uses a rivet as a pivot point, so you can rotate the stop to fit on both the left and right hand sides of a jamb. We thought that the metal tab (the part that was rotating) was twisted, as door pairs were not being hung evenly. It turns out that on both stops provided, the rivet is not straight, so no matter what, the tab will be higher on one side than the other.
This may not sound like a big deal, until you see the results. When I've hung door pairs, one door always hangs at least 1/8" lower than the other. This is VERY noticeable.
I've managed to fix this problem, but it involved serious modification and using the stop entirely differently than intended.
I would not buy this product again if I had the choice. None of the critical components worked the way they should have out of the box. This resulted in many hours trying to fix the problems with the template, and many hours trying to fix the problems this template caused.
Buy the Porter Cable instead.
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