Getting Pefect Worktop Joints with a Jig

Any woodworker with basic skills and understanding can put together a modern, functional kitchen. The one aspect, however, that typically causes problems is installing worktops. To be more specific, making joints between the adjacent boards that make the counter tops causes the most headaches. Most laminated worktops come with edges where the laminate has been rolled over a quarter-round on the leading edge of the core material. These edges can be very difficult to put together neatly and accurately without the use of a specially designed worktop jig.

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Professional worktop jigs used to be expensive and typically accessible only to professional kitchen installers. Now, however, they can often be rented, and cheaper versions are widely available. These jigs make it possible for the worktop boards to be put together at 90 degree angles. Of course, the exact layout of the kitchen can change the way the boards actually will need to be put together. Some arrangements can be very complex and require very careful measuring and cutting to ensure the proper fit. Most kitchens, however, require a simple L-shaped layout. This article assumes that the worktop is being joined for an L-shaped configuration.

Worktop jigs typically are designed to be used by professionals and are to intended to be used with a guide bush measuring 30mm and a 1/2 inch straight bit that has a cutting length of 50 mm. A 1/2 ollet router with a matching shank is often necessary because of the heavy cuts involved. Jigs are pre-drilled with several holes that are used to position for the correct set back from the rolled edge of the width of the worktop. The first step is to cut the first piece of the top to the correct length. The pins or screws must be put in place in the correct spots on the jig depending on how the jig itself is set up. Two pegs should be against the front edge of the worktop while the third will be adjustable to fit the different width tops. It is essential to have the correct orientation at all times. Some parts will be routed face up while others will be routed face down. This is done to ensure a proper fit for the joint.

When you are ready to cut, put the router in place in the slot and double check to make sure that any clamps will not be in the way of the router when cutting. It will be necessary to make several passes to cut the entire way through. It is also important to make a final pass after the cut has been completed to remove any waste and ensure that the cut has a perfectly smooth edge. The other side of the joint is cut with a similar procedure. For the mating part, the board will need to be flipped over prior to cutting. Once all the joints have been cut, it is necessary to cut recesses for the bolts that will hold the pieces together. These can also be routed using the correct template and by setting the pins in the correct location. To ensure the correct depth, measure the length of the shaft of the bolt, and add a couple millimetres.

When it is time to fit the worktops into place, first make sure that the joints will fit together tightly and evenly without any gaps or tight spots. It is a good idea to add a bit of sealant between the joints to ensure a waterproof seal. Once the worktop is in place, any excess sealant can be carefully removed.