Clarke Contractor cwj700 Instruction Manual

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.

-1-

-2-

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.

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.

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.

-3-

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).

-4-

Using The Jig

Front View

Rear 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

-5-

Standard Joints

Corner joint

using left

and

right 45º joints

90º Left

Hand Joint

90º Right

Hand Joint

45º Left

Hand Joint

45º Right

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

‘F’.

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.

Fig. 4

Female joint - laminate face up.

Cut Direction

Post Form Edge

-6-

4. Ensure the 3 pins in holes

‘F’

are pushed firmly against the post formed edge, and the

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.

11. Fully insert two pins in the jig holes marked

‘M’

with angle symbol .

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

positioning the jig on the worktop.

Fig. 5

13. Ensure the two pins in holes

‘M’

are pushed firmly against the post form edge and

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.

Pencil Line

Male Joint - Laminate face down.

Cut Direction

Post Form Edge

-7-

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

17. Fully insert three pins in holes marked

‘CB’.

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.

Fig. 6

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

‘CB’.

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.

Fig. 7

Male bolt recesses -

Laminate face down.

Post Form Edge

-8-

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.

2. Fully insert 2 pins in the holes marked

‘F’

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

4. Ensure the 2 pins in holes

‘F’

are pushed firmly against the post form edge, and the

third pin in the worktop width hole is pushed firmly against the worktop edge.

Female joint - laminate face down.

Fig. 8

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.

8. Fully insert two pins in the jig holes marked

‘M’

with angle symbol .

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

‘M’

are pushed firmly against the post form edge and

the jig lined up on the pencil line as above (Fig. 9 overleaf).

Cut Direction

Post Form Edge

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.

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

14. Fully insert three pins in holes marked

‘CB’.

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).

IMPORTANT

Recesses must be no deeper than 20mm maximum.

Fig. 9 Pencil Line

Male Joint - Laminate face up.

Fig. 10

Female bolt recesses - Laminate face down.

-9-

Cut Direction

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

‘CB’.

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.

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

Fig. 12

-10-

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.

Example

The female joint has already been cut

(Fig. 12) the length of the male worktop

needed is 1000mm (1metre).

1000mm

Post Form Edge

-11-

Fig. 13

772mm

Pencil Line

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.

Fig. 14

1000mm

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

‘F’.

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.

Cut Direction

Post Form Edge

Fig. 15

Female joint - laminate face up.

4. Ensure the 2 pins in holes

‘F’

are pushed firmly against the post form edge of the

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.

6. Cutting - Follow steps 6 - 9 on page 6.

700mm

-12-

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

care to protect the surface.

8. Fully insert two pins in the jig holes marked

‘M’

with angle symbol .

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

‘M’

are pushed firmly against the post form edge

and the jig on the pencil line (Fig. 17).

Fig. 16

Cut Direction

Post Form Edge

-13-

Fig. 17 Pencil Line

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.

12. Cutting - Follow steps 6 - 9 on page 6.

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