DEWALT
210 Bath Road
Slough, Berks.
SL1 3YD
Tel: 01753 567055
Fax: 01759 572112
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
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