Clarke CWJ 700, CWJ 900, 6462118, 6462119 User guide

WORKTOP JIG

WORKTOP JIG

Model No: CWJ700/CWJ900

Part No: 6462118/6462119

OPERATION & MAINTENANCE

INSTRUCTIONS

0305

Please note that the details and specifications contained herein, are correct at the time of going

to print. However, CLARKE International reserve the right to change specifications at any time

without prior notice.

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Thank you for purchasing this CLARKE Worktop Jig.

Before attempting to use the jig, please read this manual thoroughly and follow the
instructions carefully. In doing so you will ensure the safety of yourself and that of others
around you, and you can look forward to the jig giving you long and satisfactory service.

CLARKE GUARANTEE

This CLARKE product is guaranteed against faulty manufacture for a period of 12
months from the date of purchase. Please keep your receipt as proof of purchase.

This guarantee is invalid if the product is found to have been abused or tampered
with in any way, or not used for the purpose for which it was intended.

Faulty goods should be returned to their place of purchase, no product can be
returned to us without prior permission.

This guarantee does not effect your statutory rights.

Specifications

Model Nos: ............................... CWJ700 & CWJ900

Part Nos: ................................... 6462118 & 6462119

Worktop Jig

 For cutting left and right standard 90º and 45º joints.

 For cutting connecting bolt recesses.

 Cuts worktops ranging from 400mm to 900mm wide (model dependant).

 Integral carry handle.

 Snap in peg storage holder, includes 3 pegs.

Replacement pegs available from your Clarke dealer.

Part No:WTJIG-01-PEGS-BK

Tools required (not supplied) for use with the worktop jig

 12mm (½”) router capable of holding a 30mm guide bush.

 30mm guide bush.
 ½” tungsten carbide router bit.
 Minimum of two quick action woodworking clamps.

NOTE: worktop corners can be shaped using one of the four corners of the jig as a
template, there are three radii (10mm, 50mm & 100mm) the fourth corner is
45º. Example shown on page 17.

Tip: wherever possible, ALWAYS cut the joint before cutting wortop to length, this allows
for rectifiication in the event of minor mistakes when cutting the joint.

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Safety Precautions

WARNING:

As with all machinery, there are certain hazards involved with their operation and

use. Exercising respect and caution will considerably reduce the risk of personal

injury. However, if normal safety precautions are overlooked or ignored, personal

injury to the operator or damage to property, may result.

1. ALWAYS Learn the equipments applications, limitations and any
specific potential hazards peculiar to it. Read and become familiar
with the entire operating manual.

2. ALWAYS use a face or dust mask if operation is particularly dusty.

3. ALWAYS check for damage. Before using tools and equipment, any
damaged should be checked to ensure that it will operate properly,
and perform its intended function. Check for alignment of moving
parts, breakage of parts, mountings and any other condition that may affect the
equipments operation. Any damage should be properly repaired or the part replaced.
If in doubt, DO NOT use. Consult expert advice.

4. ALWAYS disconnect power tools from the electric supply before servicing and when
making adjustments or changing accessories etc.

5. ALWAYS wear safety goggles, manufactured to the latest European Safety Standards.
Everyday eyeglasses do not have impact resistant lenses, they are not safety glasses.

6. ALWAYS keep work area clean. Cluttered areas and benches
invite accidents.

7. ALWAYS ensure that adequate lighting is available. A
minimum intensity of 300 lux should be provided. Ensure that
lighting is placed so that you will not be working in your own
shadow.

8. ALWAYS keep children away. All visitors should be kept a safe distance from the work
area, especially whilst working with tools particularly power tools.

9. ALWAYS maintain equipment in top condition. Keep tools/machines
clean for the best and safest performance. Follow maintenance
instructions.

10. ALWAYS handle with extreme care. Do not carry tools/machines
by the electric cable, or yank the cable to disconnect it from the
power supply.

11. ALWAYS ensure the switch is off before plugging in to mains. Avoid
accidental starting.

12. ALWAYS concentrate on the job in hand, no matter how trivial it may seem. Be aware
that accidents are caused by carelessness due to familiarity.

13. ALWAYS keep your proper footing and balance at all times,
don’t overreach. For best footing, wear rubber soled
footwear. Keep floor clear of oil, scrap wood etc.

14. ALWAYS seek assistance when lifting heavy objects
(worktops etc).

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Using The Jig

Rear View

Front View

Fig. 1

Fig. 2

Before Starting:

ALWAYS

 ensure the worktop is firmly supported on trestles or similar.

 ensure the jig is firmly secured to the worktop using no less than 2 quick

woodworking clamps or similar.

 ensure there are no obstructions in the path of the router, also the router cutter

beneath the worktop, i.e. the cutter doesn’t cut into the bench/trestle when cutting
through the worktop.

 use only good quality sharp tungsten router bits.

 cut into the post form edge (curved edge) of the worktop to avoid break out or

chipping of the laminate.

 keep the router vertical to the jig and laminate.

 keep the jig surface clean.

NEVER

 exceed 10mm depth of cut in one pass.

 remove or position the router whilst the cutter is still rotating.

PLEASE NOTE: for illustrative purposes only, all diagrams and instructions in this manual
make reference to 700mm worktops, but apply equally to all sizes of worktop ranging
from 400mm to 900mm

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Standard Joints

Corner joint

using left

and

right 45º joints

90º Left
Hand Joint

45º Right
Hand Joint

90º Right
Hand Joint

45º Left
Hand Joint

Fig. 3

Before commencing, prepare the router by removing the fence guide etc if fitted, attach
the 30mm guide bush and if available, a dust extractor, also install the cutter. Put the
router safely to one side until ready to use.

Left Hand 90º Joints

1. Female joint (Fig. 4) - prepare the worktop with laminate face up and the post

form (curved edge) towards you.

2. Fully insert three pins in the holes marked

3.Fully insert fourth pin in the hole corresponding to the worktop width (e.g.700mm).

NOTE: when inserting pins, ensure the heads finish up below the jig surface,
otherwise the router will not sit flat on the jig resulting in ill fitting joints.

Female joint - laminate face up.

‘F’.

Fig. 4

Post Form Edge

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Cut Direction

4. Ensure the 3 pins in holes

fourth pin in the hole marked with the worktop width is pushed firmly against the worktop
edge.

5. Firmly clamp the jig onto the worktop ensuring the clamps do not obstruct the router
path.

6.

Cutting-Position the router (guide bush) in the jig slot at the post form end, ensure the

router base is flush on the jig surface. Set the cut depth to 10mm max.

7.

IMPORTANT: Ensure the router is pulled towards the slot edge nearest you (Face ‘A’
Fig.4). Switch the router ON and slowly move it, held firmly against face A, until the

far end of the workpiece is reached. Switch OFF and wait for the cutter to stop
spinning.

8. Lift the router out off the slot and return it to the start position again, increase the
depth of cut a further 10mm and make a second pass. Keep repeating steps 7 & 8
until the cut is complete, i.e. the cutter is below the bottom of the worktop.

9. Switch the router OFF and wait for it to stop spinning, return the router to the start
position again. Switch ON, this time, push the router against the slot edge furthest
from you (Face ‘B’, Fig.4) and make one finishing cut AT FULL DEPTH. When finished,
switch OFF and wait for the cutter to stop spinning, remove the router and jig, store
them away safely for reuse.

10.

Male Joint (Fig. 5) - Place the worktop with the laminate face down, taking care

to protect the surface.

‘F’

are pushed firmly against the post formed edge, and the

‘M’

11. Fully insert two pins in the jig holes marked

12. Refer to page 10, (cutting to length) to determine where to mark the pencil line for

positioning the jig on the worktop.

Pencil Line

Male Joint - Laminate face down.

with angle symbol .

Cut Direction

Post Form Edge

Fig. 5

13. Ensure the two pins in holes
the jig lined up on the pencil line as above (Fig. 5).

14. Firmly clamp the jig to the worktop ensuring it doesn’t move as you do so. Ensure the

clamps do not obstruct the router path.

15.

Cutting - follow steps 6 - 9 above.

‘M’

are pushed firmly against the post form edge and

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16. Female Bolt Recesses (Fig. 6) - Place the worktop with the laminate face down.

17. Fully insert three pins in holes marked

18. Clamp the jig to the worktop ensuring the three pins are firmly pushed up to the cut

out face and the worktop edge. Ensure clamps do not obstruct the router path.

Female bolt recesses - Laminate face down.

‘CB’.

Fig. 6

Post Form Edge

19. Place the router into the front of one of the clamp bolt recesses, set the depth of

cut to 10mm max. Switch the router ON and machine the recess. When done,
switch the router OFF and wait for the cutter to stop spinning. Return the router
to the back again. Increase the depth of cut a further 10mm and machine the
recess again. When finished, switch the router OFF and wait for it to stop spinning.

20. Repeat step 19 for the other 2 recesses (other 3 recesses for 900mm worktops).

IMPORTANT

Recesses must be no deeper than 20mm maximum.

21. Male Bolt Recesses (Fig. 7) - Place the worktop with laminate face down.

22. Fully insert 3 pins in the holes marked

23. Clamp the jig to the worktop ensuring all 3 pins are pushed firmly against the

worktop. Ensure clamps do not obstruct the router path.

Post Form Edge

Male bolt recesses ­Laminate face down.

‘CB’.

Fig. 7

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24. Place the router into the front of one of the clamp bolt recesses, set the depth of
cut to 10mm max. Switch the router ON and machine the recess. When done,
switch the router OFF and wait for the cutter to stop spinning. Return the router to
the back again. Increase the depth of cut a further 10mm and machine the recess
again. When finished, switch the router OFF and wait for it to stop spinning.

25. Repeat step 24 for the other 2 recesses (other 3 recesses for 900mm worktops).

IMPORTANT

Recesses must be no deeper than 20mm maximum.

Right Hand 90º Joint

1. Female joint (Fig. 8) - prepare the worktop with the laminate face down and

the post form edge towards you.

‘F’

2. Fully insert 2 pins in the holes marked

3. Fully insert third pin in hole corresponding to the worktop width (e.g.700mm).

.

4. Ensure the 2 pins in holes
third pin in the worktop width hole is pushed firmly against the worktop edge.

Post Form Edge

‘F’

are pushed firmly against the post form edge, and the

Female joint - laminate face down.

Fig. 8

Cut Direction

5. Firmly clamp the jig onto the worktop ensuring the clamps do not obstruct the router

path.

6.

Cutting - follow steps 6 - 9 on page 6.

7.

Male Joint (Fig. 9) - Place the worktop with the laminate face up.

‘M’

8. Fully insert two pins in the jig holes marked

9. Refer to page 10, (cutting to length) to determine where to mark the pencil line for

positioning the jig on the worktop.

10. Ensure the two pins in holes
the jig lined up on the pencil line as above (Fig. 9 overleaf).

‘M’

are pushed firmly against the post form edge and

with angle symbol .

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11. Firmly clamp the jig to the worktop ensuring it doesn’t move as you do so. Ensure the
clamps do not obstruct the router path.

Cut Direction

Post Form Edge

Fig. 9

12.

Cutting - follow steps 6 - 9 on page 6.

Male Joint - Laminate face up.

Pencil Line

13.

Female Bolt Recesses (Fig. 10) - Place the worktop with the laminate face down.

14. Fully insert three pins in holes marked

15. Clamp the jig to the worktop ensuring the three pins are firmly pushed up to the cut

out face and the worktop edge. Ensure clamps do not obstruct the router path.

16. Place the router into the front of one of the clamp bolt recesses, set the depth of
cut to 10mm max. Switch the router ON and machine the recess. When done,
switch the router OFF and wait for the cutter to stop spinning. Return the router to
the back again. Increase the depth of cut a further 10mm and machine the recess
again. When finished, switch the router OFF and wait for it to stop spinning.

17. Repeat step 16 for the other 2 recesses (other 3 recesses for 900mm worktops).

‘CB’.

IMPORTANT

Recesses must be no deeper than 20mm maximum.

Female bolt recesses - Laminate face down.

Fig. 10

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Post Form Edge

18. Male Bolt Recesses (Fig. 11) - Place the worktop with laminate face down.

19. Fully insert 3 pins in the holes marked

20. Clamp the jig to the worktop ensuring all 3 pins are pushed firmly against the

worktop. Ensure clamps do not obstruct the router path.

Male bolt recesses ­Laminate face down.

‘CB’.

Post Form Edge

Fig. 11

21. Place the router into the front of one of the clamp bolt recesses, set the depth of

cut to 10mm max. Switch the router ON and machine the recess. When done,
switch the router OFF and wait for the cutter to stop spinning. Return the router to
the back again, increase the depth of cut a further 10mm and machine the recess
again. When finished, switch the router OFF and wait for it to stop spinning.

22. Repeat step 21 for the other 2 recesses (other 3 recesses for 900mm worktops).

IMPORTANT

Recesses must be no deeper than 20mm maximum.

Cutting To Length

1000mm

When producing a male joint left or right
hand, the position of the jig has to be
calculated. It is easier if the female joint is
cut first, leaving the gap intended for the
male part of the worktop.

Fig. 12

Example

The female joint has already been cut
(Fig. 12) the length of the male worktop
needed is 1000mm (1metre).

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772mm

Pencil Line

Fig. 13

Post Form Edge

Position the jig onto the worktop to be cut into the male piece, referring back to the
instructions for cutting 90º joints. Subtract 228mm from the intended length,

e.g. 1000mm - 228mm = 772mm. Position the worktop jig 772mm from the opposite end
of the worktop you are cutting.

Cut Direction

1000mm

Fig. 14

Left Hand 45º Joints

1. Female joint (Fig. 15) - Refer to the diagrams on the different joints available.

Prepare the worktop with the laminate face up and the post form edge towards
the left.

2. Fully insert 2 pins in the holes marked

3. Position the jig as in Fig. 15 so that when the cut has been made, there is sufficient

length to enable trimming to length, see Fig. 16 over.

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‘F’.

Fig. 15

Post Form Edge

Female joint - laminate face up.

Cut Direction

4. Ensure the 2 pins in holes

worktop, clamp the jig to the worktop ensuring clamps do not obstruct the router
path.

5. Once the cut is complete, remove the excess (Fig. 16 hatched area), using either
the router or a fine tooth saw.

Cutting - Follow steps 6 - 9 on page 6.

6.

‘F’

are pushed firmly against the post form edge of the

700mm

Fig. 16

7. Male Joint (Fig. 17) - Place the worktop with the laminate face down, taking

care to protect the surface.

‘M’

8. Fully insert two pins in the jig holes marked

9. Refer to page 10, (cutting to length) to determine where to mark the pencil line for

positioning the jig on the worktop.

10. Ensure the 2 pins in holes marked
and the jig on the pencil line (Fig. 17).

‘M’

are pushed firmly against the post form edge

with angle symbol .

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Cut Direction

Post Form Edge

Fig. 17

Male Joint - Laminate face down.

11. Firmly clamp the jig to the worktop ensuring it doesn’t move as you do so. Ensure the

clamps do not obstruct the router path.

Cutting - Follow steps 6 - 9 on page 6.

12.

13.

Female Bolt Recesses (Fig. 18) - Place the worktop with the laminate face down.

14. Fully insert three pins in holes marked

15. Clamp the jig to the worktop ensuring the three pins are firmly pushed up to the cut

out face and the worktop edge. Ensure clamps do not obstruct the router path.

16. Place the router into the front of one of the clamp bolt recesses, set the depth of
cut to 10mm max. Switch the router ON and machine the recess. When done,
switch the router OFF and wait for the cutter to stop spinning. Return the router to
the back again. Increase the depth of cut a further 10mm and machine the recess
again. When finished, switch the router OFF and wait for it to stop spinning.

17. Repeat step 16 for the other 2 recesses (other 3 recesses for 900mm worktops).

Pencil Line

‘CB’.

Post Form Edge

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IMPORTANT

Recesses must be no deeper than 20mm maximum.

Female bolt recesses - Laminate face down.

Fig. 18

18. Male Bolt Recesses (Fig. 19) - Place the worktop with laminate face down.

19. Fully insert 3 pins in the holes marked

20. Clamp the jig to the worktop ensuring all 3 pins are pushed firmly against the

worktop. Ensure clamps do not obstruct the router path.

Male bolt recesses ­Laminate face down.

21. Place the router into the front of one of the clamp bolt recesses, set the depth of

cut to 10mm max. Switch the router ON and machine the recess. When done,
switch the router OFF and wait for the cutter to stop spinning. Return the router to
the back again. Increase the depth of cut a further 10mm and machine the recess
again. When finished, switch the router OFF and wait for it to stop spinning.

‘CB’.

Post Form Edge

Fig. 19

22. Repeat step 21 for the other 2 recesses (other 3 recesses for 900mm worktops).

IMPORTANT

Recesses must be no deeper than 20mm maximum.

Right Hand 45º Joints

1. Female joint (Fig. 20) - Refer to the diagrams on the different joints available.

Prepare the worktop with the laminate face down and the post form edge towards
the left.

2. Fully insert 2 pins in the holes marked

3. Position the jig as in Fig. 15 so that when the cut has been made, there is sufficient
length to enable trimming to length, see Fig. 16 page 12.

4. Ensure the 2 pins in holes

worktop, clamp the jig to the worktop ensuring clamps do not obstruct the router
path.

5. Once the cut is complete, cut off the excess, see Fig. 16.

Cutting - Follow steps 6 - 9 on page 6.

6.

‘F’

are pushed firmly against the post form edge of the

‘F’.

CAUTION

To Prevent damage to the laminate surface, take

extra care when working with laminate face down.

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Female joint - laminate face down.

Post Form Edge

Cut Direction

Fig. 20

Male Joint (Fig. 21) - Place the worktop with the laminate face up.

7.

‘M’

8. Fully insert two pins in the jig holes marked

9. Refer to page 10, (cutting to length) to determine where to mark the pencil line for

positioning the jig on the worktop.

with angle symbol .

10. Ensure the 2 pins in holes marked
and the jig on the pencil line (Fig. 17).

Pencil Line

Male Joint - Laminate face up.

‘M’

are pushed firmly against the post form edge

Post Form Edge

Cut Direction

Fig. 21

11. Firmly clamp the jig to the worktop ensuring it doesn’t move as you do so. Ensure the

clamps do not obstruct the router path.

12.

Cutting - Follow steps 6 - 9 on page 6.

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Fig. 22

Female bolt recesses - Laminate face down.

Post Form Edge

13. Female Bolt Recesses (Fig. 18) - Place the worktop with the laminate face down.

14. Fully insert three pins in holes marked

15. Clamp the jig to the worktop ensuring the three pins are firmly pushed up to the cut

out face and the worktop edge. Ensure clamps do not obstruct the router path.

16. Place the router into the front of one of the clamp bolt recesses, set the depth of
cut to 10mm max. Switch the router ON and machine the recess. When done,
switch the router OFF and wait for the cutter to stop spinning. Return the router to
the back again. Increase the depth of cut a further 10mm and machine the recess
again. When finished, switch the router OFF and wait for it to stop spinning.

17. Repeat step 16 for the other 2 recesses (other 3 recesses for 900mm worktops).

‘CB’.

IMPORTANT

Recesses must be no deeper than 20mm maximum.

18. Male Bolt Recesses (Fig. 23) - Place the worktop with laminate face down.

Fig. 23

Male bolt recesses ­Laminate face down.

Post Form Edge

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19. Fully insert 3 pins in the holes marked

20. Clamp the jig to the worktop ensuring all 3 pins are pushed firmly against the

worktop. Ensure clamps do not obstruct the router path.

21. Place the router into the front of one of the clamp bolt recesses, set the depth of
cut to 10mm max. Switch the router ON and machine the recess. When done,
switch the router OFF and wait for the cutter to stop spinning. Return the router to
the back again. Increase the depth of cut a further 10mm and machine the recess
again. When finished, switch the router OFF and wait for it to stop spinning.

22. Repeat step 21 for the other 2 recesses (other 3 recesses for 900mm worktops).

‘CB’.

IMPORTANT

Recesses must be no deeper than 20mm maximum.

1. Shaping Corners - Position jig on worktop as in Fig. 24 below.

2.

Cutting - Position the router (guide bush) on the edge of the jig at the post form end,

ensure the router base is flush on the jig surface. Set the cut depth to 10mm max.

3. Switch the router ON and slowly move the router following the edge of the jig.
Switch OFF and wait for the cutter to stop spinning.

4. Lift the router off the jig and return it to the start position again, increase the depth
of cut a further 10mm and make a second pass. Keep repeating steps 3 & 4 until
the cut is complete, i.e. the cutter is below the bottom of the worktop.

9. Switch the router OFF and wait for it to stop spinning, remove the router and jig,
store them away safely for reuse.

15mm

Post Form Edge

Cut Direction

15mm

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Fig. 24

Maintaining your worktop jig.

Your worktop jig requires no maintenance other than occasionally wiping it over with a
clean dampened soft cloth.

For ingrained dirt, a mild household cleaning agent can be used, DO NOT use any
solvents or chemicals as these can damage the jig.

Polishing with a propriety anti-static household polish, can aid the movement of the
router across the surface of the jig.

In case of loss, replacement pegs are available from your Clarke dealer.

Part No: WTJIG-01-PEGS-BK

HEALTH AND SAFETY

Always seek the assistance of an able bodied person when

lifting and manoeuvring heavy objects such as worktops

etc.

It is very important for one person to take charge, giving

very precise instructions of when and where to lift, plus how

heavy etc. the object being lifted is.

Failure to carry out this instruction could lead to serious

personal injury.

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