I'm trying to make some wood hinges. I've followed Incra's instructions to a T. The board has been planed to 0.503". The first bullnose pass, with the board flat on the router table, leaves a minuscule flat spot on the edge, just as their video shows. The next pass is made with the board up against the router fence.

So now you have 2700 of roundover on the edge of the board, like this.


When I take a caliper to it I get 0.503" for the board's thickness. As I rotate to 450 it's 0.525". At 900 it's 0.505"

The problem arises after the rest of the work is done and the holes for the pins are inserted. The hinge gets jammed.

The problem doesn't seem to be the Whiteside router bits. They look symmetrically round.

Has anyone used these jogs and had similar problems?