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OPERATION
KWJ/OSD Out Of
Square Device
90 left hand joint - (Fig. 2a-3e)
Joint (3mm-35mm Inset)
LH
90
o
1
35mm
3mm
2
Male
2a) Setting up for Left Hand 90 Female joint
2b) Swivel cams out of cut line
2c) Routing roughing cuts x5 for Left Hand 90 Female
EN
Joint (3mm-35mm Inset)
Joint (3mm-35mm Inset)
joint
LH
90
o
2d) Routing finishing cut for Left Hand 90 Female joint
90
o
RH
2e) Cutting bolt recess slots for female 90 connecting
1
3
bolt
3a) Setting up for Left Hand 90 Male joint
35mm
35mm
3b) Swivel cams out of cut line
3mm
2
Male
3mm
3c) Routing roughing cuts x5 for Left Hand 90 Male joint
4
Male
3d) Routing finishing cut for Left Hand 90 Male joint
3e) Cutting bolt recess slots for Male 90 connecting bolt
90 right hand joint - (Fig. 4a-5e)
Joint (3mm-35mm Inset)
90
o
RH
2
2
4
4
Male
Male
Female
Female
Male
Male
3
1
1
3
3
40mm
35mm
Cut with
3mm
Cut with
4
Male
laminate up
laminate down
4a) Setting up for Right Hand 90 Female joint
4b) Swivel cams out of cut line
4c) Routing roughing cuts x5 for Right Hand 90 Female
joint
2
2
4
4
4d) Routing finishing cut for Right Hand 90 Female joint
α
Female
Female
4e) Cutting bolt recess slots for female 90 connecting
Male
Male
Male
Male
Setup for routing along cut face
bolt
PF
1
1
3
3
5a) Setting up for Right Hand 90 Male joint
Cutter
CL
5b) Swivel cams out of cut line
Cut with
Cut with
5c) Routing roughing cuts x5 for Right Hand 90 Male
laminate up
laminate down
Start
joint
Here
Guide bush Ø30mm
Sub base
5d) Routing finishing cut for Right Hand 90 Male joint
5e) Cutting bolt recess slots for Male 90 connecting bolt
8.5mm
8.5mm
Template
Start
ß
Here
Setup for routing along cut face
CL
PF
PF
CL
CL
Joint (3mm-35mm Inset)
EN - KWJ900P
Start
LH
90
o
Start
Here
Here
1
8.5mm
35mm
8.5mm
Square End Routing of Worktops
8.5mm
8.5mm
3mm
2
Male
Start
Start
Here
CL
Here
CL
40mm
EN
Joint (3mm-35mm Inset)
12,7mm
90
PF
PF
3
The jig can be used to square cut the worktop using the
central slot. Engraved lines on the jig correspond to the
g.inside
3mm
edge of the worktop. Up to 700mm wide worktops can
4
Male
be square cut using the central slot as a router guide.
Follow the cutting instructions on previous pages to cut
PF
the worktop.
CL
Peninsular Joint
Start
Ensure router bit tip clears
Here
12,7mm
underside by 3mm
Cut 1
2
2
3mm
Cut 1
Female
Female
UNIBASE
Male
Male
Cut 2
Male
Male
8mm
8.5mm
8.5mm
40mm
1
1
3
3
Cut 3
Cut 2
g.inside
Start
40mm
40mm
Cut 4
Cut with
Cut 3
Here
CL
laminate up
Cut 5
Cut 4
1
Final cut
Rout cuts
and
the curved peninsular
Cut 1
LH
PF
3mm
Female
Routing the Curved Peninsular
Cut 2
Worktop
UNIBASE
Male
Cut 3
PF
CL
CL
Cut 4
Start
Cut 5
Here
8.5mm
8.5mm
Start
Here
CL
Setup for routing along cut face
CL
Cutter
40mm
Guide bush Ø30mm
PF
-10-
CL
CL
CL
g.inside
12,7mm
Routing 3/4" BSP Hole
Cut 1
Please check hole size is suitable for
3mm
mixer tap.
CL
Cut 2
CL
Worktop
• Mark position of hole for tap in worktop.
Cut 3
• Place jig in position so that hole in jig is over hole
position.
Cut 4
• Secure the jig with clamps.
Cut 5
• Set the depth of cut for 8-10mm and plunge cut.
RH
o
Repeat at different depths until hole is routed.
Engraved lines
Engraved lines
50mm
Routing 35mm Circular Hinge Recess
35mm
CL
Ensure router bit tip clears
underside by 3mm
90
LH
o
4
4
Female
Male
Cut 1
50mm
Worktop
8mm
Male
Cut 2
Worktop
Worktop
g.inside
40mm
Cut with
Cut 3
CL
laminate down
Cut 4
• Mark the position of the hinge on the door. The centre
of the holes should be roughly 100mm from the top
Final cut
before routing
of the door to give the required support, ensure this
measurement is as accurate as possible.
90
• Position the jig on the door.
90
o
RH
o
Engraved lines
Male
Female
Male
Female
• Set the depth for 10mm.
• Repeat operation increasing the cut by 1mm, therefore
Male
setting the total depth for 11mm. (This should be
enough clearance for most hinges. Adjust this
measurement if you require holes for thicker hinge
heads).
Peninsular
cut
45
O
Angle End Cut
Ensure router bit tip clears
underside by 3mm
Cut 1
ß
CL
8mm
10mm
Cut 2
PF
Worktop
CL
Cut 3
5.5mm
Start
Sub base
Cut 4
Here
Engraved lines
Final cut
8.5mm
Template
Template
PF
10mm
40mm
10mm
PF
g.inside
CL
40mm
5.5mm
5.5mm
EN - KWJ900P
Start
Here
50mm
8.5mm
Corner Radius
8.5mm
90
90
LH
o
RH
o
R40mm or R100mm
Female
Male
Female
Male
Female
Male
Male
PF
CL
40mm
Start
Here
Peninsular
cut
40mm
8.5mm
8.5mm
8.5mm
UNIBASE
g.inside
10mm
30mm
5.5mm
Special Note:
30mm
Due to the nature of this particular cut, the corner
90
RH
o
radius will be more awkward to edge laminate.
Female
Male
Female
Male
8.5mm
Bolt recess short connections
g.2 inside
Worktop
28mm
40mm
28mm
Worktop
Peninsular
cut
PF
PF
No.20
8.5mm
35 24
10 5
CL
3
Waterproof
10mm
PVA
PF
CL
CL
5.5mm
Start
Mini and Narrow Zip Bolts
Here
8.5mm
8.5mm
No.20
CL
PF
Waterproof
PVA
CL
40mm
28mm
Worktop
Start
Here
8.5mm
8.5mm
PF
8.5mm
-11-
Cut with laminate down
CL
Cut 2
Cut 1
Worktop
CL
CL
8mm
Cut 3
PF
Cut 2
g.2 inside
Worktop
CL
Cut 4
Cut 3
Final cut
Start
Cut 4
Here
Final cut
8.5mm
8.5mm
35 24
10 5
3
CL
CL
PF
CL
28mm
Worktop
Start
Here
28mm
Worktop
8.5mm
Cut with laminate down
Cut with laminate down
g.2 inside
CL
Cut with laminate up
Worktop
Cut with laminate up
PF
20mm
CL
Worktop
20mm
Start
Here
RH
No.20
35 24
10 5
3
8.5mm
Waterproof
PVA
g. inside
Worktop
30mm
20mm
30mm
CL
20mm
PF
CL
Start
Here
PF
PF
RH
Male
8.5mm
CL
CL
Tape
Measure
Cut with laminate down
CL
Cut with laminate up
Ø6mm
30mm
Female
Ø6mm
30mm
Ø6mm
30mm
Ø6mm
30mm
CL
30mm
20mm
PF
g.
M
Workto
Worktop
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