900mm Worktop Router Jig
Instuction Manual
SAFETY INSTRUCTIONSIt is important to read and understand your instruction manual
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Before Cutting.Children should always be kept at a safe distance from your work. Make your workshop childproof. Lock tools away where children can't get access to them. Accidents occur where benches and work areas are cluttered or dirty, floors must be kept clean, avoid working where the floor is slippery due to sawdust or wax. Always ensure that the worktop is supported properly and secured firmly to a bench or trestle before cutting. Always use the Router accessories according to manufacturer’s instructions, read and understand the instruction manual before use. Switch of and disconnect Router from the mains when not in use, before servicing and changing the cutter. Always use good quality tungsten router bits. Maintain cutters by keeping them clean and sharp for safer performance. Do not use damaged cutters. Before using any power tool, check first for damaged parts and if found, do not use them before the part or parts have been replaced with new ones. Do not use power tools in the rain or we environments. Do not use power tools when you are tired or have been drinking alcohol. Do not use power tools where there is a risk of fire or explosion - i.e. near flammable liquids or gases. Before using the jig, we recommend you practice a few joints with off-cuts of worktops or other materials to familiarise yourself with the jig.
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During Cutting.Always ensure that the path of the router is kept clear of any obstruction e.g. clamps. Always ensure that the cable of the router is clear of the jig and is of sufficient length. Do not switch router on with the cutter touching the work piece. Always work from left to right when cutting. This is safer and gives a better finish. Do not force the router to work fast. This will result in a poor quality cut and can also damage expensive router bits. Never remove the router from the jig whilst it is still in motion. Always allow the router to stop and switch off before removing. Always keep the router base parallel to the jig, and the router in an upright position. Failure to do so will cause an unmatched joint. Don’t over reach; keep proper footing at all times to ensure correct balance. Wear safety goggles at all times, everyday glasses are not sufficient for eye protection as lenses are not impact resistant and could shatter. Use a face or dust mask if operation is likely to be dusty and ear defenders during periods of operations. Don’t wear loose clothing, neckties or jewellery or other items which may get caught in moving parts. Wear non-slip footwear, cover or tie back long hair and roll long sleeves above the elbow.
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Please remember – we always recommend you practice routing and jointing a piece of waste worktop before attempting the job!
Right Hand 90° Joint
Setting Up for a Right Hand 90° Female Joint
1. Place worktop face up with postformed edge towards you.
2. Place three pins in the holes marked F90.
3. Place the fourth pin the hole marked 400, 450, 500, etc. depending on the width of the worktop.
4. Position the jig making sure all four pins are pushed firmly against the worktop edge.
5. Secure the jig with clamps.
Routing for a Right Hand 90° Female Joint
1. Set the depth of cut for 8 -10mm for your first roughing cut.
2. Position the router on the left hand side of the slot and start cutting by pulling the router towards the edge of the slot
closest to you.
3. Increase the depth of cut and repeat until the roughing cut is completed.
4. For the finish cut, position the router on the left hand side of the slot (with the router set for the full depth of cut) and cut
by pushing the router towards the edge of the slot furthest away from you.
Cutting Bolt Recess Slots for Female 90° Connecting Bolt
1. Place worktop face down with the postformed edge towards you.
2. Place three location pins in the holes marked Z.
3. Place the jig making sure all three pins are pushed firmly against the edge of the worktop.
4. Secure the jig with clamps.
5. The bolt recess should be approximately 20mm deep for 30mm worktop and 28mm deep for 40mm worktop.
6. Repeat for all the slots required.
Setting Up for a Right Hand 90° Male Joint
1. Place worktop face down and postformed edge towards you.
2. Place two pins in the holes marked M90.
3. Position the jig making sure both pins are pushed firmly against the worktop edge.
4. Secure the jig with clamps.
Routing for Right Hand 90° Male Joint
1. Set the depth of cut for 8 -10mm for your first roughing cut.
2. Position the router on the left hand side of the slot and start cutting by pulling the router towards the edge of the slot
closest to you.
3. Increase the depth of cut and repeat until the roughing cut is completed.
4. For the finish cut, position the router on the left hand side of the slot (with the router set for the full depth of cut) and cut
by pushing the router towards the edge of the slot furthest away from you.
Cutting Bolt Recess Slots for Male 90° Connecting Bolt
1. Place worktop face down.
2. Place three location pins in the holes marked Z.
3. Place the jig making sure all three pins are pushed firmly against the edge of the worktop.
4. Secure the jig with clamps.
5. The bolt recess should be approximately 20mm deep for 30mm worktop and 28mm deep for 40mm worktop
6. Repeat for all the slots required.
Left Hand 90° Joint
Setting Up for a Left Hand 90° Female Joint
1. Place worktop face down and postformed edge towards you.
2. Place three pins in the holes marked F90.
3. Place the fourth pin the hole marked 400, 450, 500, etc. depending on the width of the worktop.
4. Position the jig making sure all four pins are pushed firmly against the worktop edge.
5. Secure the jig with clamps.
Routing for a Left Hand 90° Female Joint
1. Set the depth of cut for 8 -10mm for your first roughing cut.
2. Position the router on the left hand side of the slot and start cutting by pulling the router towards the edge of the slot
closest to you.
3. Increase the depth of cut and repeat until the roughing cut is completed.
4. For the finish cut, position the router on the left hand side of the slot (with the router set for the full depth of cut) and cut
by pushing the router towards the edge of the slot furthest away from you.
Cutting Bolt Recess Slots for Female 90° Connecting Bolt
1. Place worktop face down with the postformed edge towards you.
2. Place three location pins in the holes marked Z.
3. Place the jig making sure all three pins are pushed firmly against the edge of the worktop.
4. Secure the jig with clamps.
5. The bolt recess should be approximately 20mm deep for 30mm worktop and 28mm deep for 40mm worktop edge.
6. Repeat for all the slots required.
Setting Up for a Left Hand 90° Male Joint
1. Place worktop face up with the postformed edge towards you.
2. Place two pins in the holes marked M90.
3. Position the jig making sure both pins are pushed firmly against the worktop edge.
4. Secure the jig with clamps.
Routing for a Left Hand 90° Male Joint
1. Set the depth of cut for 8-10mm for your first roughing cut.
2. Position the router on the left hand side of the slot and start cutting by pulling the router towards the edge of the slot
closest to you..
3. Increase the depth of cut and repeat until the roughing cut is completed.
4. For the finish cut, position the router on the left hand side of the slot (with the router set for the full depth of cut) and cut
by pushing the router towards the edge of the slot furthest away from you.
Cutting Bolt Recess Slots for Male 90° Connecting Bolt
1. Place worktop face down as shown.
2. Place three location pins in the holes marked Z.
3. Place the jig making sure all three pins are pushed firmly against the edge of the worktop.
4. Secure the jig with clamps.
5. The bolt recess should be approximately 20mm deep for 30mm worktop and 28mm deep for 40mm worktop
6. Repeat for all the slots required.
Right Hand 45° Joint
Setting up for a Right Hand 90° Female Joint
1. Place worktop face up with postformed edge as shown.
2. Place 2 pins in the holes marked F45.
3. Position the jig making sure the back of the jig is lined up with the pencil mark (650mm from the centre line – see
cutting to size diagram).
4. Make sure both pins are pushed firmly against the worktop edge.
5. Secure the jig with clamps.
Routing for a Right Hand 45° Female Joint
1. Set the depth of cut for 8-10mm for your first roughing cut.
2. Position the router on the left hand side of the slot and start cutting by pulling the router towards the edge of the slot
closest to you.
3. Increase the depth of cut and repeat until the roughing cut is completed.
4. For the finish cut, position the router on the left hand side of the slot (with the router set for the full depth of cut) and cut
by pushing the router towards the edge of the slot furthest away from you.
Cutting Bolt Recess Slots for Male 45° Female Joint
1. Place worktop face down as shown.
2. Make sure the shaded area is cut off for the appropriate width of the worktop (see cutting to size diagram).
3. Place three location pins in the holes marked Z.
4. Place the jig making sure all three pins are pushed firmly against the edge of the worktop.
5. Secure the jig with clamps.
6. The bolt recess should be approximately 20mm deep for 30mm worktop and 28mm deep for 40mm worktop
7. Repeat for all the slots required.
Setting up for a Right Hand 45° Male Joint
1. Place worktop face down with postformed edge as towards you.
2. Place 2 pins in the holes marked M45.
3. Position the jig as shown making sure both pins are pushed against the worktop edge.
4. Secure the jig with clamps.
Routing for a Right Hand 45° Male Joint
1. Set the depth of cut for 8-10mm for your first roughing cut.
2. Position the router on the left hand side of the slot and start cutting by pulling the router towards the edge of the slot
closest to you.
3. Increase the depth of cut and repeat until the roughing cut is completed.
4. For the finish cut, position the router on the left hand side of the slot (with the router set for the full depth of cut) and cut
by pushing the router towards the edge of the slot furthest away from you.
Cutting Bolt Recess Slots for a Male 45° Connecting Bolt
1. Place worktop face down as shown.
2. Place three location pins in the holes marked Z.
3. Place the jig making sure all three pins are pushed firmly against the edge of the worktop.
4. Secure the jig with clamps.
5. The bolt recess should be approximately 20mm deep for 30mm worktop and 28mm deep for 40mm worktop
6. Repeat for all the slots required.
Left Hand 45° Joint
Setting Up for a Left Hand 45° Female Joint
1. Place the worktop face down with the postformed edge towards you.
2. Place 2 pins in holes marked F45
3. Position the jig making sure the back of the jig is lined up with the pencil mark (650mm from the centre line – see
cutting to size diagram).
4. Secure the jig with clamps.
Routing for a Left Hand 45° Female Joint
1. Set the depth of cut for 8-10mm for your first roughing cut.
2. Position the router on the left hand side of the slot and start cutting by pulling the router towards the edge of the slot
closest to you.
3. Increase the depth of cut and repeat until the roughing cut is completed.
4. For the finishing cut, position the router on the left hand side of the slot (with the router set to make the full depth of cut) and then make the cut by pushing the router towards the edge of the slot furthest away from you. 
Cutting Bolt Recess Slots for a Female 45° Connecting Bolt
1. Place worktop face down as shown.
2. Make sure the shaded area is cut off for the appropriate width of the worktop (see cutting to size diagram).
3. Place three location pins in the holes marked Z.
4. Place the jig making sure all three pins are pushed firmly against the edge of the worktop.
5. Secure the jig with clamps.
6. The bolt recess should be approximately 20mm deep for 30mm worktop and 28mm deep for 40mm worktop
7. Repeat for all the slots required.
Setting up for a Left Hand 45° Male Joint
1. Place the worktop face up with the postformed edge towards you.
2. Place 2 pins in holes marked M45
3. Position the jig making sure both pins are pushed firmly against the worktop edge.
4. Secure the jig with clamps.
Routing for a Left Hand 45° Male Joint
1. Set the depth of cut for 8-10mm for your first roughing cut.
2. Position the router on the left hand side of the slot and start cutting by pulling the router towards the edge of the slot
closest to you.
3. Increase the depth of cut and repeat until the roughing cut is completed.
4. For the finish cut, position the router on the left hand side of the slot (with the router set for the full depth of cut) and cut by pushing the router towards the edge of the slot furthest away from you.
Cutting Bolt Recess Slots Female 45° Connecting Bolt
1. Place worktop face down as shown.
2. Place three location pins in the holes marked Z.
3. Place the jig making sure all three pins are pushed firmly against the edge of the worktop.
4. Secure the jig with clamps.
5. The bolt recess should be approximately 20mm deep for 30mm worktop and 28mm deep for 40mm worktop
6. Repeat for all the slots required.
Curved Peninsular
Locate the template on the worktop and line up by eye, ensuring the jig is laid at least 8mm in from the edges of the worktop to allow for the cutter and guide bush offset, then secure the jig with clamps
When cutting the curved peninsular, hold the router guide bush against the edge of the template. Cut from left to right.
It is recommended that depth stops are used and at least three or four cuts taken.
Square end routing of worktops
The jig can be used to square cut the worktop using the central slot. Engraved lines on the jig correspond to the edge of the worktop. Up to 650mm wide worktops can be square cut using the central slot as a router guide. Follow the cutting instructions on previous pages to cut the worktop.