Using a Worktop Jig
A standard worktop jig is designed to be used from both sides. The jig typically has several different holes drilled into it so that it can accept pins. If spare pin sets are available for your jig, it is a good idea to invest in them. The markings on a worktop jig can vary greatly, but the letters “C”, “M”, and “F” are commonly used. Holes marked “C” are used to cut butterfly bolt slots. “M” holes are used when you are cutting male joints, and “F” holes are intended to be used to cut female joints. Because these markings can differ, it is important to double check your particular jig’s instruction manual to be sure.
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When cutting, it is common to first cut the female part of a joint. This can be done with the rolled edge of the worktop toward you and the laminated surface uppermost. Leaving the factory wrapping in place while cutting can help to prevent any accidental marks. To begin, place a pin in the correct width hold. Three additional pins should also be inserted into the jigs female holes. These pins should be placed against the post-formed edge while the width pin should be against the right edge of the piece. Next, the jig must be clamped to the worktop, and the worktop must also be securely clamped down. Before beginning, make sure that the clamps will not get in the way of the router and that everything is secure.
Before you cut, mount the correct guide bush and insert a high quality cutter that is of the correct length and size for the project. Only use sharp, high quality cutters because this will ensure the best possible result. Begin cutting from the left, taking care not to remove too much. Once the router is fully stopped, remove and reposition the jig and repeat the cut after adjusting the depth. This process is continued until the joint has been fully cut.
When you are ready to cut the male part of the joint, place the laminate face down and use the other face of the jig. The majority of jigs come with detailed but simple instructions for calculating the correct position of the jig in order to ensure that the correct male length is cut. Two pins need to be inserted into the male holes, and the pins should be squarely registered against the edge that has been post-formed. Clamp the jig and worktop in place as you did with the female cuts, and cut in a similar procedure.
Once both pieces have been cut, it is necessary to cut the slots for butterfly bolts in the underside. It is best to take care of the female bolt recesses prior to the male. Put the piece on the bench face down. Pins need to be inserted in the connector holes on the jig and registered against the female cut-out. Once the jig has been clamped in position, set the cutting depth as needed, and make several light passes until the recess has been made. Any rough edges can be cleaned with a sharp blade. If you also need to cut a corresponding male part, determine the male length needed by measuring in the female joint.