DeWalt DE6242 User Manual

DEWALT
210 Bath Road
Slough, Berks.
SL1 3YD

Tel: [phone]
Fax: [phone]
www.dewalt.co.uk

Copyright DEWALT 01/06

DE6242

IFU 087.5

ADDITIONAL EQUIPMENT REQUIRED:

• ELECTRIC HAND ROUTER

• 30mm ROUTER GUIDE BUSH

• TUNGSTEN CARBIDE ROUTER CUTTER - 12.7mm DIA X 50mm (1/2” DIA X 2”)

• MINIMUM OF 2 QUICK ACTION, ‘G’ CLAMPS OR SCREW CLAMPS

Page 2

FACE 1

Left & Right Hand

90° Joints

FACE 2

Left & Right

Hand 45°

For 500, 600, 616, 650. 700,

720, 740, 900 & 920mm Wide

Worktops

Holder for

flush fitting

location pegs

Rout recesses for Worktop

Connecting Bolts

Carrying Handle

Edge of jig to cut

indicator

Edge of jig to cut

indicator

Denotes Female Denotes Male

Slot for screw

clamp

Slot for screw

clamp

DE6289

Cutting to Length for 45° Joints only

When producing a male joint, left or
right handed and where the worktop
turns through 45°, the position of the
cut 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.

Example

The female joint has already been cut
(see left diagram) and the length of
the male worktop needed is 1000mm
(1 metre).

Position your worktop jig onto the laminate referring back to the instructions on 45° joints.

Subtract 293mm from the intended length - (this dimension is engraved on the jig and relates to
the distance from the bottom edge of the jig to where the edge of the cut will be).

E.g. 1000mm – 292 = 708mm

Position the worktop jig 708mm from the opposite end of the laminate you’re cutting (see bottom
left diagram)

After the cut, a 1000mm length laminate is left.

Change the 1000mm figure used in this example for whatever length you require.

1000mm

708mm

1000mm

Page 15

1. MALE JOINT Prepare the male worktop
with the laminate face up.

2. Insert 2 pins in holes marked ♂ 45°.

3. Refer to the page on ‘cutting to length’ on
page 15 to find out where to mark the pencil
line to determine the position of the jig along
the length of the worktop.

4. Make sure the 2 pins in the holes marked
♂ 45°are firmly pushed against the post
formed edge (see diagram X)

5. Clamp the jig to the worktop checking that
both pins are still against the worktop. Make
sure the clamps will not obstruct the router
path.

6. Follow steps 6 to 10 for cutting the worktop.

7. CUTTING METHOD Position the
router in the far left side of the slot.
Set the router to cut a depth of
10mm.

8. IMPORTANT - Position the router

in the slot and cut from left to right,
pulling the router against the edge
of the slot closest to you.

9. Remove the router, and start again
from the far left of the central slot, but
increase the depth a further 10mm.

10. Follow steps 7 – 9, until cut is
complete.

For the final finishing cut, position

the router again in the far left side
of the slot, and set the router to cut at the full depth of the worktop. Again, cut from left to right but
apply the pressure to the edge furthest away from you

11. MALE BOLT RECESSES
Prepare the male worktop with the
laminate face down.

12. Insert 3 pins in the holes marked
’B’.

13. Make sure the 3 pins are firmly
pushed against the front cut out and
the edge of the worktop (see diagram
Z).

14. Clamp the jig to the worktop
checking that all 3 pins are still firmly
against the worktop. Make sure the
clamps will not obstruct the router path.

15. You will need a depth of 20mm for
the worktop connectors. Do not
exceed 10mm per cut.

16. Cut the bolt recesses out, each
time clearing the waste material after
each cut.

Right Hand 45° Male Joints

Page 14

DIAGRAM X

MALE JOINT­LAMINATE FACE UP

DIAGRAM Y

DIAGRAM Z

MALE JOINT­LAMINATE FACE
DOWN

Protecting the Environment

Separate Collection
This product must not be disposed of with normal household waste.

Should you find one day that your DEWALT product needs replacement, or
it is of no further use to you, do not dispose of it with household waste. Make
this product available for separate collection.

Separate collection of used products and packaging allows material to be recycled and used again. Re-use
of recycled materials helps prevent environmental pollution and reduces the demand for raw materials.

Local regulations may provide for separate collection of electrical products
from the household, at municipal waste sites or by the retailer when you
purchase a new product.

DEWALT provides a facility for the collection and recycling of DEWALT
products once they have reached the end of their working life. To take
advantage of this service please return your product to any authorised repair
agent who will collect them on our behalf.

You can check the location of your nearest authorised repair agent at the address indicated in this manual.
Alternately, list of authorised DEWALT repair agents and full details of our after-sales service and contacts
are available on the internet at: www.2helpU.com

Page 3

GUARANTEE

• ONE YEAR FULL WARRANTY •

If your DEWALT product becomes defective due to faulty materials or workmanship within 12 months of the
date of purchase, we will guarantee to replace all defective parts free of charge or, at our discretion, replace
the unit free of charge provided that:

• The products was not misused.

• Repairs have not been attempted by unauthorised persons.

• Proof of purchase date is produced.

This guarantee is offered as an extra benefit and is additional to consumers statuary rights.

For the locations of your nearest authorised DEWALT repair agent, please use the appropriate telephone
number on the back of this manual. Alternatively, a list of authorised repair agents are available on the
internet at www.2helpU.com

Page 4

1. FEMALE JOINT Refer to the diagrams on
the different joints available.

2. Prepare the female worktop with the laminate
face down and the post formed (curved edge)
towards the left.

3. Insert 2 or 3 pins in the holes marked ♀ 45°
(see diagram T)

4. Slide the jig along the length of the worktop so
that when cut is made, the joint face is a little
longer than the worktop width. Once the jointing
face has been cut, there will be enough length
for the male worktop to fit (minor adjustment
may be necessary (see diagram P).

5. Make sure the 2 or 3 pins in the holes marked ♀
45° are firmly pushed against the front post formed edge.

6. Clamp the jig to the worktop checking that both pins
are still against the worktop. Make sure the clamps will
not obstruct the router path.

7. Once the cut is complete, cut off the excess
(Diagram V), so that the distance from point 1 to point 2
is equal to your worktop width.

8. CUTTING Position the router in the far left side
of the central slot. Set the router to cut a depth of 10mm.

9. IMPORTANT - Position the router in the slot and
cut from left to right, pulling the router against the
edge of the slot closest to you.

10. Remove the router, and start again from the far left
of the central slot, but increase the depth a further
10mm.

11. Follow steps 8 – 10, until cut is complete.

12. For the final finishing cut, position the router again
in the far left side of the central slot, and set the router
to cut at the full depth of the worktop. Again, cut from
left to right but apply the pressure to the edge furthest
away from you.

13. FEMALE BOLT RECESSES Prepare
the female worktop with the laminate
face down.

14. Insert 3 pins in the holes marked ‘B’ (see
diagram W).

15. Make sure the 3 pins are firmly pushed
against the front cut out and the edge of
the worktop.

16. Clamp the jig to the worktop checking
that all 3 pins are still firmly against the
worktop. Make sure the clamps will not
obstruct the router path.

17. You will need a depth of 20mm for the
worktop connectors. Do not exceed 10mm per cu t.

18. Cut the bolt recesses out, each time clearing the waste material after each cut. .

DIAGRAM V

FEMALE JOINT–
TRIM WORKTOP

Cut off

Point 1

Point 2

Right Hand 45° Female Joints

DIAGRAM W

FEMALE BOLT RECESS ­LAMINATE FACE DOWN

Page 13

DIAGRAM T

FEMALE JOINT­LAMINATE FACE
DOWN

Worktop

Width

DIAGRAM U

1. MALE JOINT Prepare the male worktop
with the laminate face down.

2. Insert 2 pins in holes marked ♂ 45°.

3. Refer to the page on ‘cutting to length’ on page
15 to find out where to mark the pencil line to
determine the position of the jig along the
length of the worktop.

4. Make sure the 2 pins in the holes marked ♂
45° are firmly pushed against the post formed

edge (see diagram Q)

5. Clamp the jig to the worktop checking that both
pins are still against the worktop. Make sure the
clamps will not obstruct the router path.

6. Follow steps 6 to 10 for cutting the worktop.

7. CUTTING METHOD Position the router
in the far left side of the slot. Set the router
to cut a depth of 10mm.

8. IMPORTANT - Position the router in

the slot and cut from left to right, pulling
the router against the edge of the slot
closest to you.

9. Remove the router, and start again from
the far left of the central slot, but increase
the depth a further 10mm.

10. Follow steps 7 – 9, until cut is complete.

11. For the final finishing cut, position
the router again in the far left side of the
slot, and set the router to cut at the full
depth of the worktop. Again, cut from left
to right but apply the pressure to the
edge furthest away from you.

12. MALE BOLT RECESSES Pre­pare the male worktop with the laminate
face down.

13. Insert 3 pins in the holes marked ’B’.

14. Make sure the 3 pins are firmly
pushed against the front cut out and the
edge of the worktop (see diagram S).

15. Clamp the jig to the worktop check­ing that all 3 pins are still firmly against
the worktop. Make sure the clamps will
not obstruct the router path.

16. You will need a depth of 20mm for
the worktop connectors. Do not exceed
10mm per cut.

17. Cut the bolt recesses out, each time
clearing the waste material after each
cut.

Left Hand 45° Male Joints

Page 12

DIAGRAM Q

MALE JOINT ­LAMINATE FACE DOWN

DIAGRAM R

DIAGRAM S

MALE BOLT RECESS ­LAMINATE FACE DOWN

Safety Notes

This jig will enable you to cut …….

Before starting ……...

• Never cut worktop to length until all joints are complete and have been checked for

correct fit.

• Make sure the worktop is secured firmly to the bench or trestle.

• Ensure that the jig is firmly secured to the worktop.

• Ensure there are no obstructions in the path of the router e.g. clamps or bench.

• Always use good quality sharp router bits

• Always wear eye protection when cutting.

• Always wear ear protection if cutting for long periods

• Always cut from left to right.

• Always cut into post formed edge to avoid breakout or chipping.

• Always keep the router vertical to the jig and worktop.

• Never exceed 10mm depth of cut in one pass.

• Never remove the router from the jig or position the router whilst cutter is still rotating.

The cutter may cut into the jig and damage the bush location faces.

Page 5

CORNER JOINT ­USING THE RIGHT HAND
AND LEFT HAND 45°
JOINTS

STANDARD LEFT & RIGHT HAND 90° JOINTS

45° JOINTS ­RIGHT AND LEFT
HAND

Female Male Male

Female

Female

Female

Female

Female

Male

Male

Male

Page 6

1. FEMALE JOINT Refer to the diagrams
on the different joints available.

2. Prepare the female worktop with the
laminate or sealed prepared surface,
face up and the post formed (curved
edge) towards you.

3. For all 90° joints, the jig should be
placed with the logo uppermost.

4. Insert 3 pins in the holes marked ♀.

5. Insert the 4th pin in the hole dependant
on your worktop width. e.g. As in the
example shown, if your worktop is
700mm wide then insert the 3rd pin in the hole marked 700 (see diagram A).

6. Make sure the 3 pins in the holes marked with ♀ are firmly pushed against the front post formed edge and the pin
in the hole marked with the worktop width is pushed firmly against the edge of the worktop (see diagram A)

7. Clamp the jig to the worktop checking that all 3 pins have not moved away from the worktop. Make sure the

8. CUTTING METHOD Position the router in the far left side of the slot. Set the router to cut a depth of 10mm.

9. IMPORTANT - Position the router in the slot and cut from left t o right, pulling the router against the edge
of the slot closest to you.

10. Remove the router, and start again from the far left of the central slot, but increase the depth a further 10mm.

11. Follow steps 8 – 9, until cut is complete.

13. FEMALE BOLT RECESSES
Prepare the female worktop with
the laminate or prepared surface
face down.

14. Insert 3 pins in the holes which
are marked B.

15. Make sure the 3 pins are firmly
pushed against the front cut out
and the edge of the worktop (see
diagram C).

16. Clamp the jig to the worktop
checking that all 3 pins are still
firmly against the worktop. Make
sure the clamps will not obstruct
the router path.

17. You will need a depth of 20mm for the worktop connectors. Do not exceed 10mm per cut.

18. Cut the bolt recesses out, each time clearing the waste material after each cut.

90° Female Joints - Left Side

DIAGRAM A

FEMALE JOINT ­LAMINATE FACE UP

DIAGRAM C

FEMALE BOLT RECESS ­LAMINATE FACE DOWN.

DIAGRAM B

Using G-clamp

Using Screw
clamp
DE6289

1. FEMALE JOINT Refer to the diagrams

on the different joints available. For 45° joints
the jig should always be placed with the logo
facing down.

2. Prepare the female worktop with the laminate
face up and the post formed (curved edge )
towards the left.

3. Insert 2 or 3 pins in the holes marked ♀ 45°
(see diagram M)

4. Slide the jig along the length of the worktop
so that when cut is made, the joint face is a
little longer than the worktop width. Once the
jointing face has been cut, there will be
enough length for the male workto p to fit
(minor adjustment may be necessary (see
diagram O).

5. Make sure the 2 or 3 pins in the holes marked

♀ 45° are firmly pushed against the front post formed

edge.

6. Clamp the jig to the worktop checking that both
pins are still against the worktop. Make sure the
clamps will not obstruct the router path.

7. Once the cut is complete, cut off the excess
(Diagram O), so that the distance from point 1 to point
2 is equal to your worktop width.

8. CUTTING Position the router in the far left side
of the central slot. Set the router to cut a depth of
10mm.

9. IMPORTANT - Position the router in the slot and

cut from left to right, pulling the router against the
edge of the slot closest to you.

10. Remove the router, and start again from the far left of
the central slot, but increase the depth a further
10mm.

11. Follow steps 8 – 10, until cut is complete.

12. For the final finishing cut, position the router again in
the far left side of the central slot, and set the router to
cut at the full depth of the worktop. Again, cut from left
to right but apply the pressure to the edge furthest
away from you.

13. FEMALE BOLT RECESSES Prepare the female worktop with the
laminate face down.

14. Insert 2 pins in the holes marked ’B’ and 1 pin into
the hole marked with a ‘B’ and ♂ 45°. (see diagram P).

15. Make sure the 3 pins are firmly pushed against the
front cut out and the edge of the worktop.

16. Clamp the jig to the worktop checking that all 3
pins are still firmly against the worktop. Make sure the
clamps will not obstruct the router path.

17. You will need a depth of 20mm for the worktop
connectors. Do not exceed 10mm per cut.

18. Cut the bolt recesses out, each time clearing the
waste material .after each cut.

DIAGRAM O

FEMALE JOINT–
TRIM WORKTOP

Cut off

Point 1

Point 2

Left Hand 45° Female Joints

Worktop

Width

DIAGRAM M

FEMALE JOINT­LAMINATE FACE UP

DIAGRAM P

FEMALE BOLT RECESS ­LAMINATE FACE DOWN

Page 11

DIAGRAM N

1000mm

Cutting to Length for 90° Joints only

1000mm

Page 10

Intended location of
worktop with male cut

723mm

When producing a male joint, left or right handed
and where the worktop turns through 90°, the posi­tion of the cut 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.

Example

The female joint has already been cut (see left dia­gram) and the length of the male worktop needed is
1000mm (1 metre).

Position your worktop jig onto the laminate referring
back to the instructions on 90° joints.

Subtract 277mm from the intended length (this di­mension is engraved on the jig and relates to the
distance from the bottom edge of the jig to where
the edge of the cut will be).

E.g. 1000mm – 277 = 723mm

Position the worktop jig 723mm from the opposite
end of the laminate you’re cutting (see bottom left
diagram)

After the cut, a 1000mm length laminate is left.

Change the 1000mm figure used in this example for
whatever length you require.

Page 7

1. MALE JOINT Prepare the male worktop
with the laminate or prepared surface face
down.

2. Insert 2 pins in holes marked ‘♂ 90°’.

3. Refer to the page on ‘cutting to length’ on
page 10 to find out where to mark the pencil
line to determine the position of the jig along
the length of the worktop.

4. Make sure the 2 pins in the holes marked
’♂ 90°’ are firmly pushed against the post
formed edge (see diagram D)

5. Clamp the jig to the worktop checking that
both pins are still against the worktop. Make
sure the clamps will not obstruct the router
path.

11. MALE BOLT RECESSES Prepare the
male worktop with the laminate or prepared
surface face down.

12. Insert 2 pins in the holes marked ’B’ and 1
pin in the hole marked with both a ‘B’ and

♂ 90°. (see diagram F).

13. Make sure the 3 pins are firmly pushed
against the front cut out and the edge of the
worktop.

14. Clamp the jig to the worktop checking that all
3 pins are still firmly against the worktop.
Make sure the clamps will not obstruct the
router path.

15. You will need a depth of 20mm for the work­top connectors. Do not exceed 10mm per
cut.

16. Cut the bolt recesses out, each time clearing
the waste material after each cut.

90° Male Joints - Left Side

DIAGRAM D

MALE JOINT—
LAMINATE FACE
DOWN

DIAGRAM F

MALE BOLT RECESS ­LAMINATE FACE DOWN.

6. CUTTING METHOD Position the router in
the far left side of the slot. Set the router to
cut a depth of 10mm.

7. IMPORTANT - Position the router in the

slot and cut from left to right, pulling the
router against the edge of the slot closest
to you.

8. Remove the router, and start again from the
far left of the central slot, but increase the
depth a further 10mm.

9. Follow steps 6 – 8, until cut is complete.

10. For the final finishing cut, position the
router again in the far left side of the slot,
and set the router to cut at the full depth
of the worktop. Again, cut from left to
right but apply the pressure to the edge
furthest away from you.

DIAGRAM E

Page 8

1. FEMALE JOINT Refer to the
diagrams on the different joints avail­able. Prepare the female worktop
with the laminate face down and the
post formed (curved edge) towards
you.

2. Insert 3 pins in the holes marked ♀.

3. Insert the 4th pin in the hole depend­ant on your worktop width, e.g. If
your worktop is 700mm wide then
insert the 4th pin in the hole marked
700 (see diagram G).

4. Make sure the 3 pins in the holes
marked F are firmly pushed against
the front post formed edge and the pin in the hole marked with the worktop width is pushed firmly against the
edge of the worktop.

5. Clamp the jig to the worktop double-checking that all 4 pins are still against the worktop. Make sure the clamps
will not obstruct the router path.

6. CUTTING METHOD

7. Refer to the instructions on page 6

for cutting method.

8. FEMALE BOLT RECESSES
Prepare the female worktop with the
laminate face down.

9. Insert 3 pins in the holes marked
’B’ (see diagram C).

10. Make sure the 3 pins are firmly
pushed against the front cut out and
the edge of the worktop (see diagram
I)

11. Clamp the jig to the worktop checking
that all 3 pins are still firmly against the
worktop. Make sure the clamps will not
obstruct the router path.

12. You will need a depth of 20mm for the
worktop connectors. Do not exceed
10mm per cut.

13. Cut the bolt recesses out, each time
clearing the waste material after each cut.

90° Female Joints - Right Side

DIAGRAM G

FEMALE JOINT ­LAMINATE FACE DOWN

DIAGRAM I

FEMALE BOLT RECESS ­LAMINATE FACE DOWN.

DIAGRAM H

Page 9

9. MALE BOLT RECESSES
Prepare the male worktop with the
laminate face down.

10. Insert 2 pins in the holes marked B
and 1 pin in the hole marked with

both ‘B’ and ‘♂ 90°’.(see diagram L).

11. Make sure the 3 pins are firmly
pushed against the front cut out and
the edge of the worktop.

12. Clamp the jig to the worktop checking
that all 3 pins are still firmly against
the worktop. Make sure the clamps
will not obstruct the router path.

13. You will need a depth of 20mm for
the worktop connectors. Do not
exceed 10mm per cut.

14. Cut the bolt recesses out, each time
clearing the waste material after each cut.

1. MALE JOINT Prepare the male
worktop with the laminate face up.

2. Insert 2 pins in holes marked ‘♂ 90°.
(see diagram J)

3. Refer to the page on ‘cutting to
length’ to find out where to mark the
pencil line to determine the position of
the jig along the length of the
worktop.

4. Make sure the 2 pins in the holes
marked ♂ 90° are firmly pushed
against the post formed edge.

5. Clamp the jig to the worktop checking
that both pins are still against the
worktop.

6. Make sure the clamps will not
obstruct the router path.

7. CUTTING METHOD

8. Refer to the instructions on page 7 for
cutting method.

90° Male Joints - Right Side

DIAGRAM J

MALE JOINT—
LAMINATE FACE UP

DIAGRAM L

MALE BOLT RECESS—
LAMINATE FACE DOWN.

DIAGRAM K