PowerKiss Jig User manual
PowerKiss
Router Jig
PowerKiss Router Jig User Guide
Version 2.0
© PowerKiss 2011
3
Important information - read before proceeding
• PowerKiss Router Jig is compatible with all plunge-capable routers that
can be fitted with a 17mm copy ring. If a 17mm ring is not available for your
router, you can fit the following subplate and ring: http://www.trend-uk.
com/en/FI/productlist/4/1008/Universal_Sub-base.html
• The PowerKiss Router Jig is an accessory for handheld routers. Always
use powertools and their accessories according to manufacturer’s
instructions; read and understand the instruction manuals before the use
• The PowerKiss Router Jig is designed to be used for milling wooden
or wood-based surfaces and should not be used for carving metal or
distinctly fragile surfaces (consisting or containing e.g. high amount of
paper, cardboard or glass)
• Use PowerKiss Router Jig for only in surfaces with thickness of 15-50mm
• PowerKiss is not responsible for third-party products and their quality
before or after the installation; the person conducting the milling should
always consult the manufacturer of the target surface before starting the
work to ensure compatibility
Contents
Important information - read before proceeding 3
Selecting the place for the milling 5
Tools for the installation 6
Introducing PowerKiss Router Jig 7
Properties 7
The ready groove 7
Using the PowerKiss Router Jig 8
STEP I - Preparing the table 8
STEP II - Attaching the jig 9
STEP III - Placing the router 10
STEP IV - Setting the plunge depth 11
STEP V - Using the router 12
STEP VI - Checking the groove 13
Additional safety instructions 14
5
400mm
200mm
center of the charging area
Selecting the place for
the milling
The PowerKiss Router Jig is designed
to assist making a suitable milling for
PowerKiss Heart installation.
The place for the milling may
be selected freely, however the
requirements above must be fulfilled.
Below is a picture of recommended
place for the charging area. More
detailed information about the
positioning of the charging area is
available at powerkiss.com or by
request.
The PowerKiss Hotspot must be located so
that it is at least:
• 200mm from the user's body in horizontal direction
• 250mm from the user's body in vertical direction
• 300mm from another charging area
6
Plunge router
Copy ring with 17 mm dia
suitable for the router
Router bit with 8 mm or 10 mm
dia and sufficient overall length
(e.g. OAL ≥ 80 mm with 50 mm
thick surfaces)
Tools for the installation
Power or
cordless drill
Vacuum cleaner
Digital caliper Measuring
tape
3.5mm
drill bit
T20 bit
1
6.00 mm
Ø 8 mm or 10 mm
OAL
Ø 17 mm
7
Introducing PowerKiss
Router Jig
Properties
34
±1
68
±1
A A
4
±0,5
3,5
+
0,1
SECTION A-A
Rout out dimensions
table_sample
PowerKiss Oy
12.1.2011
tal
WEIGHT:
A4
SHEET 1 OF 1
SCALE:1:2
FILE NAME:
PART NUMBER/DESCRIPTION:
REVISION
DO NOT SCALE DRAWING
MATERIAL:
DATE
SIGNATURE
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
Q.A
MFG
APPV'D
CHK'D
DRAWN
Guide hole
for the router
Holes for attaching
the jig in phase 1
Holes for attaching
the jig in phase 2
Center hole for
positioning the jig
(in both phases)
Dimensions
width 150mm
length 180mm
height 8mm
The ready groove
8
Using the PowerKiss
Router Jig
STEP I - Preparing the table
Drill a hole of d= 3.5mm through the
surface of the furniture at the desired
place for the PowerKiss Heart.
Measure the table surface thickness
with extreme care, use the digital
caliper.
If possible, turn the piece of furniture
over, so it is facing the floor or similar
solid ground.
2
0
.0
0
m
m
3.5mm
9
STEP II - Attaching the jig
Position the jig by fastening a
countersink screw through the center
hole of the jig to the drilled 3.5mm hole.
Ensure that the jig is able to turn freely
using the screw as a center point
Attach the jig firmly to the surface with
two countersink screws from the holes
depicted in the picture
10
STEP III - Placing the router
Attach the router bit and the 17 mm
copy ring to the router.
Place the router on the jig so that copy
ring sits securely in the guide hole,
being tightly against the edge of the
hole
11
STEP IV - Setting the plunge
depth
Set the router plunge depth so that the
router is on the jig, thus including the
thickness of the jig in the plunge depth.
The thickness of the surface in the
finished groove must be exactly 4 mm
(±0.5 mm). Pay special attention to the
plunge depth setting of the router and
re-measure the furniture surface if you
are not sure of its thickness.
- 4 mm =
+
2
0
.0
0 m
m
8 mm20 mm
24 mm
For example, in case of 20 mm thick
table top the router must be set to
plunge eventually 24 mm deep (20 mm
+ 8 mm - 4 mm = 24 mm) in order to
get 4 mm thick surface in the finished
groove. Notice that you should not
exceed 10 mm depth in one cut!
12
STEP V - Using the router
Turn on the router and plunge it slowly
allowing the bit to cut into the furniture
surface. As the set depth is reached,
guide the router against the edges of
the guide hole so that the fixture of the
guide is processed to the surface. Press
the router firmly against the surface
and the edges of the guide hole.
Regarding the plunge depth, with thick
materials and small routers only plunge
part of the way, do a complete round,
plunge more and repeat until final
depth is reached. The cutting length
of the router bit and material affects
the process, the harder the material,
the smaller is the initial plunge depth.
In some cases you have to do several
plunges in order to reach the target
depth adequately
Turn off the router and remove it
carefully from the jig plate. Clean all
possible residues and detach the
screws from the side holes. Turn the jig
180° and attach the jig with the screws
from other side holes depicted in the
picture. Place the router on the jig
again and drill out the remaining of the
groove.
180°
13
STEP VI - Checking the
groove
As the target fixture (see properties of
ready groove) has been processd to
the surface, remove the jig and ensure
that the thickness of the surface is
exactly 4 mm (±0.5) in the finished
groove. If necessary, do a another
round of processing. Also, check that
the inner diameter of the hole is 34mm
(±1 mm) and the outer diameter is 68
mm (±1 mm).
34 mm
(±1)
68 mm
(±1)
2
0
.0
0
m
m
= 4 mm (±0.5)
-
16.
0
0 mm
For example, in case of 20 mm thick
table top the ready groove should be
16 mm deep in order to have 4 mm
thick surface in the finished groove (20
mm - 16 mm = 4 mm)
14
Additional safety instructions
• PowerKiss Router Jig is compatible with all plunge-capable routers that
can be fitted with a 17mm copy ring. If a 17mm ring is not available for your
router, you can fit the following subplate and ring: http://www.trend-uk.
com/en/FI/productlist/4/1008/Universal_Sub-base.html
• Switch of and disconnect router from the mains when not in use, before
servicing and changing the cutter
• Before using any power tool, check first for damaged parts and if found,
do not use them before the part or parts have been replaced with new
ones
• Before using the jig, we recommend you practice a few joints with off-cuts
of worktops or other materials to familiarize yourself with the jig
• Always ensure that the path of the router is kept clear of any obstruction
e.g. clamps
• Always ensure that the cable of the router is clear of the jig and is of
sufficient length
• Do not switch router on with the cutter touching the work piece
• Do not force the router to work fast. This will result in a poor quality cut
and can also damage expensive router bits
• Never remove the router from the jig whilst it is still in motion
• Always allow the router to stop and switch off before removing
• Always keep the router base parallel to the jig, and the router in an
upright position. Failure to do so will cause an unmatched joint
15
© PowerKiss 2011
www.powerkiss.com
• Don’t over reach; keep proper footing at all times to ensure correct
balance
• Wear safety goggles at all times, everyday glasses are not sufficient for
eye protection as lenses are not impact resistant and could shatter. Use
a face or dust mask if operation is likely to be dusty and ear defenders
during periods of operations
• Don’t wear loose clothing, neckties or jewellery or other items which may
get caught in moving parts. Wear non-slip footwear, cover or tie back long
hair and roll long sleeves above the elbow
• Never exceed 10mm depth cut in one cut
• Be sure to set plunge depth correctly, plunging through the table will
remove the centre plug that guides the jig and create a serious hazard
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