1
CONTRACT JIG
2
Section 1.
1.01
Jigs are used in quality installation of kitchen, bedroom and bathroom furniture. This jig is
manufactured from a composite material to the highest tolerance on CNC machinery to ensure a
perfect finish. This material will withstand water, solvents, adhesives and cleaning agents often
used in the installation of kitchens.
Before starting please take some time to read through these instructions carefully. The jig has
been designed to be as easy as possible to use, however we recommend that, if you are
inexperienced, you practice on off-cuts prior to the first installation. Please observe all relevant
safety requirements for the use of routers.
The jig can be used to fit 90° and 45° corners for worktops of widths 500, 600, 616 and 650 mm.
By using shims other worktop widths can be accommodated.
This jig will work with most hand routers including Dewalt, Bosch and Makita. A 30 mm guide bush and
a ½” (12.7mm) tungsten tipped cutter are required. No other combination will work satisfactorily.
Router Base
Guide
Bush
½" cutter
30 mm diameter guide bush
SAFETY FIRST
1. Make sure all cables are clear of the router.
2. Make sure the work piece is correctly supported.
3. Always use protective goggles when using the router.
4. A dust mask should be worn when performing cuts.
5. Do not switch router on with blade touching the work.
6. Never remove the router when it is switched on and moving.
7. Make sure there are no obstructions to the path of the router.
8. READ INSTRUCTIONS CAREFULLY BEFORE STARTING THE WORK.
3
1.02 CONVENTIONS and IMPORTANT POINTS
I
t is important that you work the router from left to right.
Working from right to left is with the cutter’s direction. This might cause lack of control resulting in
damage to the jig or even injury. Don’t plunge more that 10 mm at a time or use blunt tools
Ensure the guide bush is firmly attached to the router base plate.
Make sure the pegs are well seated and are not proud of the surface of the jig.
When working with the centre slot, always use the side nearest to you first for the waste removal,
followed by the side furthest from you for the finished edge.
When clamping the jig in position check the pegs are still in contact with the worktop. Certain
types of clamp, if over tightened, can cause the jig to creep out of position.
Ensure the router cutter remains perpendicular when performing all cuts; this is particularly
important when performing cuts with the worktop face down.
When making some male cuts you may find it more convenient to remove larger pieces of waste
with a jigsaw prior to making the router cuts.
SECTION 2.0 90º CORNER
The drawing below shows a typical kitchen lay-out with the terms used in these
instructions superimposed.
Left Male
Right Male
Right Female
Left Female
Worktop
Postformed Edge
Postformed Edge
Postformed Edge
Worktop
Worktop
35mm Inset
4
2.01 Female Joints
FE MA L E 9 0 -FINISHING CUT EDGE
M A L E 45 -FINISH ING CUT EDGE
TH IS SIDE UP FOR FEMALE 90 CUTS
AN D MALE 45 CUTS
MANUFACTURED
TOP FACE OF WORKTOP
POSTFORMED EDGE
PEGS
Fig. 1 Right hand female set up
POSTF ORMEDEDGE
WO RK TOP
FA C E U P - RH JOINT
FA C E D OWN - LH JOINT
FE M A LE - USE LF + RF HOLE S +
WO RK TO P WIDTH HOLES
F E MA L E 90 -FINIS HING CUT EDGE
MA L E 4 5 -FINIS HING CUT EDGE
THIS SIDE UP FOR FEMALE 90 CUTS
AN D MALE 45 CUTS
MANUFACTURE D
BACK OF WORKTOP
POSTFORMED EDGE
PEGS
Fig. 2 Left hand female set up
POSTFORMEDEDGE
WO RK TOP
FA C E U P - RH JOINT
FA C E D OWN - L H JOI NT
FE M AL E - USE LF + RF HOLES +
WO RK TO P WIDTH HOLES
Fig. 1 and Fig. 2 show the jig set up to cut female sections of a 600mm wide worktop. For
worktops of different widths it will be necessary relocate the peg shown in the 600 width hole to
one of the other worktop width holes.
Set the jig on the worktop as shown. Clamp firmly with G-clamps. Position the router in extreme
bottom left-hand point of the centre slot. Set the cutting depth to 10 mm.
Start the router and pass the router steadily along the centre slot using the side of the slot nearest
you to guide the router.
5
Repeat this process increasing the depth of cut by 10 mm for each pass until the post-form edge
has been removed.
With the cutter set to maximum depth, use the side of the slot furthest from you to guide the
router and make one pass to remove approximately 1mm of worktop leaving a perfect cut edge.
Switch off the router at the end of each pass and do not remove the router from the jig until you are
sure that the router has stopped. Avoid contact between tool and jig.
2.02 Male Joint
THIS SIDE UP FOR MALE 90 CUTS
AND FEMALE 45 CUTS
MALE 90 -FINISHING CUT EDGE
FEMALE 45 -FINISHI NG CUT EDGE
Fig. 3 Right hand male set up
BACK OF WORKTOP
POSTFORMED EDGE
WORKTOP
FACE DOWN - R H JOIN T
FACE UP - LH JOINT
MALE - USE LM + RM HOLES
PEGS
MALE 90 -ROUGH CUT EDGE
FEMALE 45 -ROUGH CUT EDGE
THIS SIDE UP FOR MALE 90 CUTS
AND FEMALE 45 CUTS
MALE 90 -FINISHING CUT EDGE
FEMALE 45 -FI NISHING CUT ED GE
Fig. 4 Left hand male set up
TOP FACE OF WORKTOP
POSTFORMED EDGE
WORKTOP
FACE D OWN - RH JOIN T
FAC E UP - LH JOINT
MALE - USE LM + RM HOLES
PEGS
FEMALE 45 -ROUGH CUT EDG E
MALE 90 -ROUGH CUT EDGE
Set the jig on the worktop as shown in Fig. 3 and 4 (depending on whether the cut is a left or
right). Clamp firmly with G-clamps. Position the router in extreme left-hand point of the centre slot
and proceed as described above for the female joints.
Note These instructions set up the jig to cut 90° corner s. If you wish to allow for slightly out of
square walls the method for this is described later in the instructions.
6
2.03 Bolt Slots
THIS SIDE UP FOR MALE 90 CUTS
AND FEMALE 45 CUTS
MALE 90 -FINISHING CUT EDGE
FEMALE 45 -FIN ISHING CUT EDGE
Fig. 5 Female Right hand Bolt slots
BACK OF WORKTOP
POSTFORMED EDGE
PEGS
WORKTOP
FACE DOWN - RH JOINT
FACE U P - LH JOINT
MALE - USE LM + RM HOLES
MALE 90 -R OUGH CUT EDGE
FEMALE 45 -ROUGH CUT EDGE
FEMALE 90 -FINISHING CUT EDGE
MALE 45 -FINISHING CUT EDGE
THIS SIDE UP FOR FEMALE 90 CUTS
AND MALE 45 CUTS
MANUFACT UR ED
Fig. 6 Female Left hand Bolt slots
BACK OF WORKTOP
POSTFORMED EDGE
PEGS
POST FORM ED EDG E
WORKTOP
FACE UP - RH JOINT
FACE DOWN - LH JOINT
FEMALE - USE LF + RF HOLES +
WORKTOP WIDTH HOLES
FEMALE 90 -ROUGH CUT EDGE
MALE 45 -ROUGH C UT EDGE
7
FEMALE 90 -FINIS HING CUT EDGE
M ALE 45 -FINISHING CUT EDGE
MANUFACTURED
Fig. 7 Right hand Male Bolt Slots
POSTFORMED EDGE
BACK OF WORKTOP
PEGS
THIS SIDE UP FOR FEMALE 90 CUTS
AND MALE 45 CUTS
POS TF ORM ED ED GE
WORKTOP
FACE UP - RH JOINT
FACE DO WN - LH JOINT
FEMALE - USE L F + RF HOLES +
WORKTOP WIDTH HOLE S
FEMALE 90 -ROUGH CUT EDGE
M AL E 45 -ROUGH CUT EDGE
M ALE 90 -FINISHING CUT EDGE
FEMALE 45 -FINIS HING CUT EDG E
Fig. 8 Left hand Male Bolt Slots
POSTFORMED EDGE
BACK OF WORKTOP
PEGS
THIS SIDE UP FOR MALE 90 CUTS
AND FEMALE 45 CUTS
FEMALE 4 5 -ROUGH CUT EDGE
W ORKTOP
F AC E DOWN - RH JOINT
F AC E UP - LH JOINT
M ALE - U SE LM + RM HOLES
M ALE 90 - ROUGH CUT EDGE
Place pegs in the holes marked B then clamp the jig in position with G clamps as shown in the
figures above.
For bolt holes the plunging depth should be set to about 20mm. Ensure this is sufficient to
accommodate your joining bolt you are using. Work clockwise around each mushroom shaped
slot and remove all the waste. Depending on the worktop width only 2 slots may be needed.
8
SECTION 3.0 45° CORNER JOINTS
L
i
n
e
o
f
f
r
o
n
t
o
f
u
n
i
t
s
600
The dimensions shown in the drawings below are based on a 600 mm worktop width and will produce
corner section suitable for a 600 mm unit. The minimum length of worktop required for a corner section is
1600 mm.
3.01 Female Joints
Place the worktop corner piece face-up and mark a centre line. If using a 600mm deep worktop,
mark two lines 640 mm either side of the centre line on the back edge of the worktop and the
same on the face. For a 616 mm deep worktop these lines should be 656mm from the centre line
and 690 mm for a 650 mm deep worktop.
T
H
IS
SID
E
U
P F
O
R
M
AL
E
9
0
CU
T
S
A
N
D
FE
M
AL
E
45
C
U
TS
MAL
E 90
-FI
NIS
HIN
G C
UT
ED
GE
FE
MA
LE 4
5 -F
INI
SHI
NG
CU
T E
DG
E
640.000
POSTFORMED EDGE
TOP FACE OF WORKTOP
Centre Line
Fig. 9 Right hand Corner Female
WORKTOP
F
ACE
DO
WN
- R
H J
OIN
T
FA
CE
UP
- LH
JO
IN
T
MA
LE - U
SE
LM
+
RM
HO
LE
S
MAL
E 90
-R
OUG
H
CU
T E
DGE
FEM
ALE
45
-RO
UG
H C
UT
ED
GE
9
T
H
I
S
S
I
D
E
U
P
F
O
R
M
A
L
E
9
0
C
U
T
S
A
N
D
F
E
M
A
L
E
4
5
C
U
T
S
M
A
LE
9
0 -
FI
N
IS
H
IN
G
C
U
T
E
D
G
E
F
E
MA
L
E
45
-F
IN
I
S
HI N
G
C
U
T
E
D
GE
640.000
POSTFORMED EDGE
BACK OF WORKTOP
Centre Line
Fig. 10 Left hand Corner Female
W
O
R
K
T
O
P
FA
C
E
D
OW
N
- R
H
JO
IN
T
F
AC
E
U
P
-
L
H
JO
I
N
T
M
A
LE
-
US
E
L
M
+
RM
H
O
LE
S
M
AL
E
90
-
R
OU
GH
C
UT
E
D
G
E
F
EM
A
LE
4
5
-R
O
U
G
H
C
U
T
E
D
GE
The jig, used as a straight edge, can help with marking out on this type of corner. With the jig face side
down, place pegs in the 2 holes joined by engraved arrows labeled CFR+CFL. Offer the jig up against the
post-form edge and align the top edge of the jig with the right-hand 640mm mark. Clamp in position and
check again for correct alignment. Cut the 45° corner in a like way to that used for the 90° corner. To finish
the corner, offer the male section to the cut edge and mark the position of the back edge on the centre
section. Accurately remove with a saw, the “Cut Off” end, as shown in Fig. 11 below
6
0
0
640
Off
Cut
Centre Line
Fig. 11
10
3.02 Male Joints
FEMALE 90 -FI NISHIN G CUT EDGE
MALE 45 -FIN ISHING CUT EDGE
THIS SIDE UP FOR FEMALE 90 CUTS
AND MALE 45 CUTS
MANUFACTURED
Fig. 12 Right hand Corner Male
BACK OF WORKTOP
POSTFORMED EDGE
MALE 45 -ROUGH CUT EDGE
FEMALE 90 -ROUGH CUT EDGE
POSTF ORM ED E DGE
WORKTOP
FACE UP - R H JOIN T
FACE DOWN - LH JOINT
FEMALE - USE LF + RF HOLES +
WORKTOP W IDTH HOLES
FEMALE 90 -FI NISHING CUT EDGE
MALE 45 -FIN ISHING CUT EDGE
THIS SIDE UP FOR FEMALE 90 CUTS
AND MALE 45 CUTS
MANUFACTURED
Fig. 13 Left hand Corner Male
TOP FACE OF WORKTOP
POSTFORMED EDGE
MALE 45 -ROUGH CUT EDGE
FEMALE 90 -ROUGH CUT EDGE
PO ST FO RM ED ED GE
WORKTOP
FACE UP - RH JOINT
FACE DOWN - LH JOINT
FEMALE - USE LF + RF H OLES +
WORKTOP WIDTH HOLES
Place pegs in the holes labeled “CMR + CML” with the jig face up, and offer them firmly against the post-
formed edge. Clamp in position and check again to ensure all pegs are in contact with the post-form edge
and the jig is in position. Route worktop as described above.
3.03 Bolt Slots
See Fig. 5, 6, 7 and 8 above.
11
Section 4.0 Addenda
4.01 Other U Shape Lay-outs
The “Typical Lay-out” on page 3 is the best method of constructing a U shaped layout. There are however
other formats which may be used for example the two lay-outs below. These may be necessary depending
on worktop length available, location of sink, hob etc.
The layouts above are preferable to that below. If however it is necessary to use this construction, careful
measurement is required to ensure a good fit.
WORKTOP 1
WORKTOP 2
WORKTOP 3
PO STFORMED EDGE
POSTFORMED EDGE
5. DRAW "LINE C"
LINE C IS LENGTH B MINUS 228mm FROM MALE CUT
6. SET JIG ON LINE C AS SHOWN BELOW AND CLAMP
7. CUT MALE MITRE ON LEFT HAND END OF WORKTOP 3
INSET 35MM
4. CUT MALE MITRE ON RIGHT HAND END OF W'TOP 3
3. MEASURE DISTANCE BETWEEN MITRE CUTS - "B ABOVE"
2. INSTALL WOKKTOPS 1 & 2
1. CUT FEMALE MITRES ON WORKTOPS 1 & 2
POSTFORMED EDGE
LINE C
B
228
For the set up above, the cut on the left hand edge of worktop 3 is lined as shown below:
12
Worktop Back
Postformed Edge
Peg
.
Line C
“Out of Square” Walls.
In some situations it may be necessary to adjust the angle of the male cut in order to overcome walls that
are not of 90°.
To accomplish this it is recommended that you first cut and fit the female joint of the worktop, whether this
be right or left. Next, identify which side up you are going to need the worktop when cutting the male, i.e.
face up for a left hand male or face down for a right hand male.
Depending on which one it is, you must then either overlay or underlay the male worktop on or below the
already fitted female worktop, with the back edge of the male worktop flat against the wall it is to be fitted
to (see Fig. 14).
P
O
S
T
F
O
R
M
E
D
E
D
G
E
POSTFORMED EDGE
W
A
L
L
W
A
L
L
W
A
L
L
WALLWALLWALL
Female worktop
Male worktop
Fig. 14 out of square male line up
13
Fig. 14 shows the male worktop overlaying the female worktop for a right hand corner. Where the worktop
will face down when it is cut. A pencil should be used to scribe along the cut edge of the female worktop
onto the back face of the worktop that is to be the male cut.
Fig. 15 shows how the jig should be lined up against the pencil mark using only one of the pegs in the male
cut holes.
T
H
I
S
S
I
D
E
U
P
F
O
R
M
A
L
E
9
0
C
U
T
S
A
N
D
F
E
M
A
L
E
4
5
C
U
T
S
M
A
L
E
9
0
-
F
I
N
I
S
H
I
N
G
C
U
T
E
D
G
E
F
E
M
A
L
E
4
5
-
F
I
N
I
S
H
I
N
G
C
U
T
E
D
G
E
Scribed pencil line
One peg only
POSTFORMED EDGE
BACK OF WORKTOP
Fig. 15 Jig line up out of square
The above procedure can be successfully executed only if the angle of the out of square is no more than 3°
either way. More than this and the join will not match up adequately. However, 3° over the length of a 3m
worktop is equivalent to approximately 160mm out from one end to the other. Therefore walls would have
to be considerably out of square to require more than this angle.
14
Troubleshooting Guide
Problem Probable Cause Remedy
Poor finish on male/female joint faces Incomplete routing process.
Ensure final stroke against far edge of
centre slot is performed.
Sharp angle near post-form edge on
male/female
Incomplete routing process
Ensure final stroke against far edge is
performed.
Good finish but male & female don’t
match up
Incorrect size of cutter and/or
guide bush.
Ensure 12.7mm cutter and 30mm guide
bush - nothing else is suitable.
Inconsistent results
-wandering edges.
Loose guide bush. Ensure guide bush is firmly attached to
the router base
Irregular gaps on RH male and/or LH
female face.
Poor router control Ensure the cutter remains absolutely
perpendicular on these cuts.
Poor/chipped cut edges
Blunt or poor quality router
blades
Ensure only sharp, premium quality
router bits are used.
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14
Unika TLS0600 Operating instructions
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