DeWalt DE6241 User manual

DEWALT
210 Bath Road
Slough, Berks.
SL1 3YD
Tel: [phone]
Fax: [phone]
www.dewalt.co.uk
Copyright DEWALT06/06
DE6241

IFU 104.5
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 OR ‘G’ CLAMPS
Page 2
Left & Right Hand
90° Joints
Left & Right Hand
45° Joints
For 420, 500, 600, 616, 620 ,
650 & 720mm Wide Worktops
Location holes for flush fitting
location pegs
Rout recesses for Worktop
Connecting Bolts
Rout recesses for
100mm x 50mm
desk top cable tidy
inserts. & carrying
handle
Worktop pegs
storage facility
Rout recesses for
80mm circular desk
top cable tidy
inserts.
Denotes Female Denotes Male
Location slot for
screw clamp
DE6289

Right Hand 45° Joints
DIAGRAM A
FEMALE JOINT-
WORKTOP FACE
DOWN
DIAGRAM C
MALE JOINT -
WORKTOP FACE UP
DIAGRAM D
FEMALE BOLT RECESS -
WORKTOP FACE DOWN
DIAGRAM B
FEMALE JOINT– TRIM
WORKTOP
Cut off
Point 1 Point 2
Page 10
1. FEMALE JOINT Refer to the diagrams on the different
joints available. For the female cut in your worktop, position the
jig as shown in diagram A and the worktop face down with the
post formed (curved edge) towards you.
2. Insert 2 or 3 pins in the holes marked ‘♀∡’.
3. Slide the jig along the length of the worktop, 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
B)
4. Make sure the pins in the holes marked ’♀∡’are firmly pushed
against the front post formed edge (see diagram A)
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. Once the cut is complete, cut off the excess (Diagram B), so
that the distance from point 1 to point 2 is equal to your worktop
width.
7. CUTTING Position the router in the far left side of the
central 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 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.
12. MALE JOINT For the male cut in your worktop, prepare the
worktop face up and turn the jig over from the face used
previously.
13. Insert 2 pins in holes ‘♂.
14. Refer to the page on ‘cutting to length’ on page 8 to find out
where to mark the pencil line to determine the position of the jig
along the length of the worktop.
15. Make sure the 2 pins in the holes marked ’♂’are firmly pushed
against the post formed edge (see diagram C)
16. 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.
17. Follow steps 6 to 10 for cutting the worktop.
18. FEMALE BOLT RECESSES Take the worktop into which you
have cut the female cut and position the worktop face down.
19. Insert 4 pins in the holes which have a symbol resembling a
worktop connector bolt recess as indicated in diagram D.
20. Make sure the 4 pins are firmly pushed against the front cut out
and the edge of the worktop (see diagram D).
21. Clamp the jig to the worktop checking that all 4 pins are still
firmly against the worktop. Make sure the clamps will not
obstruct the router path.
22. You will need a depth of 20mm for the worktop connectors. Do
not exceed 10mm per cut.
23. Cut the bolt recesses out, each time clearing the waste material
after each cut. .
24. MALE BOLT RECESSES Prepare the male worktop with the
worktop face down.
25. Insert 4 pins in the holes which have a symbol resembling a
worktop connector bolt recess as indicated in diagram D.
Follow instructions on male bolt recesses on the page referring
to right hand 90 degree joints.
Worktop
Width
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
DIAGRAM A
FEMALE JOINT-
WORKTOP FACE UP
DIAGRAM C
MALE JOINT -
WORKTOP FACE DOWN
DIAGRAM D
FEMALE BOLT RECESS -
WORKTOP FACE DOWN
DIAGRAM B
FEMALE JOINT–
TRIM WORKTOP Cut off
Point 1 Point 2
Left Hand 45° Joints
Page 9
1. FEMALE JOINT Refer to the diagrams on the different
joints available. For the female cut in your worktop, position the
jig as shown in diagram A and the worktop face up with the
post formed (curved edge) towards you.
2. Insert 2 or 3 pins in the holes marked ’♀∡’ .
3. Slide the jig along the length of the worktop, 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 B)
4. Make sure the pins in the holes marked ’♀∡’ are firmly pushed
against the front post formed edge (see diagram A)
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. Once the cut is complete, cut off the excess (Diagram B), so
that the distance from point 1 to point 2 is equal to your
worktop width.
7. CUTTING Position the router in the far left side of the central
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 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.
12. MALE JOINT For the male cut in your worktop, prepare the
worktop face down and turn the jig over from the face used
previously.
13. Insert 2 pins in holes marked ‘d’.
14. Refer to the page on ‘cutting to length’ on page 8 to find out
where to mark the pencil line to determine the position of the
jig along the length of the worktop.
15. Make sure the 2 pins in the holes marked ’d’ are firmly pushed
against the post formed edge (see diagram C)
16. 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.
17. Follow steps 6 to 10 for cutting the worktop.
18. FEMALE BOLT RECESSES Take the worktop into which
you have cut the female cut and position the worktop face
down.
19. Insert 4 pins in the holes which have a symbol resembling a
worktop connector bolt recess as indicated in diagram D.
20. Make sure the 4 pins are firmly pushed against the front cut
out and the edge of the worktop (see diagram D).
21. Clamp the jig to the worktop checking that all 4 pins are still
firmly against the worktop. Make sure the clamps will not
obstruct the router path.
22. You will need a depth of 20mm for the worktop connectors. Do
not exceed 10mm per cut.
22. Cut the bolt recesses out, each time clearing the waste
material after each cut.
23. MALE BOLT RECESSES Take the worktop into which you
have cut the male cut and position the worktop face down.
24. Insert 4 pins in the holes which have a symbol resembling a
worktop connector bolt recess as indicated in diagram D.
Follow instructions on male bolt recesses on the page referring
to left hand 90 degree joints.
Worktop
Width

1000mm
Cutting to Length
782mm
1000mm
Page 8
When producing a male joint, left or right hand, the
position of the worktop 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 worktop referring back to
the instructions on 90° joints.
Subtract 218mm from the intended length
(this is the distance engraved on the front
face of the jig and is the distance from the
edge of the jig to where the cut will be)
E.g. 1000mm – 218 =782mm
Position the worktop jig 782mm from the opposite end of
the worktop you’re cutting (see bottom left diagram)
After the cut, a 1000mm length worktop is left.
Change the 1000mm figure used in this example for
whatever length you require.
Intended location of
worktop with male cut
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
STANDARD LEFT & RIGHT HAND 90° JOINTS
45° JOINTS - RIGHT
AND LEFT HAND -
MALE AND FEMALE
Female
Male Male
Female

Pencil Line
DIAGRAM B
MALE JOINT—
WORKTOP FACE
DOWN
Left Hand 90° Joints
Page 6
1. FEMALE JOINT Refer to the diagrams on the different joints
available. For the female cut in your worktop, position the jig as
shown in diagram Aand the worktop face up and the post formed
(curved edge) towards you.
2. Insert three pins in the holes marked ‘♀’.
3. Insert the 4th pin in the hole dependant on your worktop width. e.g. If
your worktop is 650mm wide (as shown in diagram A) then insert the
4th pin in the hole marked 65.
4. 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)
5. Clamp the jig to the worktop checking that all 4 pins are still against
the worktop. Make sure the clamps will not obstruct the router path.
6. CUTTING Position the router in the far left side of the central
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 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.
11. MALE JOINT For the male cut in your worktop, prepare the
worktop face down and turn the jig over from the face used
previously.
12. Insert 2 pins in holes marked ‘♂’.
13. Refer to the page on ‘cutting to length’ on page 8 to find out where to
mark the pencil line to determine the position of the jig along the
length of the worktop.
14. Make sure the 2 pins in the holes marked ‘♂’ are firmly pushed
against the post formed edge (see diagram B)
15. 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.
16. Follow steps 6 to 10 for cutting the worktop.
17. FEMALE BOLT RECESSES Take the worktop into which you have
cut the female cut and position the worktop face down.
18. Position the jig as shown in diagram C, and insert 4 pins in the
holes which have a symbol resembling a worktop connector bolt
recess as indicated on diagram C.
19. Make sure the 4 pins are firmly pushed against the front cut out and
the edge of the worktop.
20. Clamp the jig to the worktop checking that all 4 pins are still firmly
against the worktop. Make sure the clamps will not obstruct the
router path.
21. You will need a depth of 20mm for the worktop connectors. Do not
exceed 10mm per cut.
22. Cut the bolt recesses out, each time clearing the waste material after
each cut.
23. MALE BOLT RECESSES Take the worktop into which you have
cut the male cut and position the worktop face down.
24. Position the jig as shown in diagram D and insert 4 pins in the holes
which have a symbol resembling a worktop connector bolt recess -
this was shown in diagram C.
25. Make sure the 4 pins are firmly pushed against the front cut out and
the edge of the worktop.
26. Clamp the jig to the worktop checking that all 4pins are still firmly
against the worktop. Make sure the clamps will not obstruct the
router path.
27. You will need a depth of 20mm for the worktop connectors. Do not
exceed 10mm per cut.
28. Cut the bolt recesses out, each time clearing the waste material after
each cut.
DIAGRAM D
MALE BOLT RECESS -
WORKTOP FACE DOWN.
DIAGRAM C
FEMALE BOLT RECESS -
WORKTOP FACE DOWN.
DIAGRAM A
FEMALE JOINT -
WORKTOP FACE UP
Pencil Line
Right Hand 90° Joints
Page 7
1. FEMALE JOINT For the female cut in your worktop, position the
jig as shown in diagram A and the worktop face down and the post
formed (curved edge) towards you.
2. Insert three pins in the holes marked ‘♀’.
3. Insert the 4th pin in the hole dependant on your worktop width, e.g.
If your worktop is 650mm wide then insert the 4th pin in the hole
marked 65 (see diagram A).
4. Make sure the 3 pins in the holes marked ’♀’ 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)
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 Position the router in the far left side of the central 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 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.
11. MALE JOINT For the male cut in your worktop, prepare the
worktop face up and turn the jig over from the face used previously.
12. Insert 2 pins in holes marked ‘♂’.
13. Refer to the page on ‘cutting to length' on page 8 to find out where
to mark the pencil line to determine the position of the jig along the
length of the worktop.
14. Make sure the 2 pins in the holes marked ’♂’are firmly pushed
against the post formed edge (see diagram B)
15. 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.
16. Follow steps 6 to 10 for cutting the worktop.
17. FEMALE BOLT RECESSES Take the worktop into which you
have cut the female cut and position the worktop face down.
18. Position the jig as shown in diagram C, and insert 4 pins in the
holes which have a symbol resembling a worktop connector bolt
recess as indicated in diagram C.
19. Make sure the 44 pins are firmly pushed against the front cut out
and the edge of the worktop (see diagram C).
20. Clamp the jig to the worktop checking that all 4 pins are still firmly
against the worktop. Make sure the clamps will not obstruct the
router path.
21. You will need a depth of 20mm for the worktop connectors. Do not
exceed 10mm per cut.
23. Cut the bolt recesses out, each time clearing the waste material
after each cut.
23. MALE BOLT RECESSES Take the worktop into which you have
cut the male cut and position the worktop face down.
24. Position the jig as shown in diagram D and insert 4 pins in the
holes which have a symbol resembling a worktop connector bolt
recess as indicated in diagram C.
24. Make sure the 4 pins are firmly pushed against the front cut out
and the edge of the worktop (see diagram D).
25. Clamp the jig to the worktop checking that all 4 pins are still firmly
against the worktop. Make sure the clamps will not obstruct the
router path.
26. You will need a depth of 20mm for the worktop connectors. Do not
exceed 10mm per cut.
27. Cut the bolt recesses out, each time clearing the waste material
after each cut.
DIAGRAM A
FEMALE JOINT -
WORKTOP FACE DOWN
DIAGRAM B
MALE JOINT—
WORKTOP FACE UP
DIAGRAM C
FEMALE BOLT RECESS -
WORKTOP FACE DOWN.
DIAGRAM D
MALE BOLT RECESS —
WORKTOP FACE DOWN.