1. SQUARE SHEET AND ROUGH CUT TOP TO SIZE
A. Place Sheet on tables of 5/4 boards
B. Rout long edge
C. Square end of sheet
D. Square Seam
E. Place template onto the sheet and mark exact size of top
F. Rough cut sheet to approx. 1/4″ oversize
2. PREPARE SEAM
A. Rout seam with the wavy base & bit using preset 11″ Index Arms.
(This will remove 1/16″ material from each side of seam)
Remember to use the wavy base high side on one side of seam
and the low side on the other
B. Hook the whole top together without glue
C. If the top can be installed in one piece, glue together
3. RIP AND GLUE BUILD-UP AND SPLASH (Butt or Cove)
A. Build-up should be 1 7/8″ wide to set on cabinet front
B. Glue build-up pieces together. Clamp with 2″ Spring Clamps or Build-up Jig
C. Glue up Cove Splash
4. ROUT TOP TO 1/16″ OVER FINISHED SIZE
A. Place the Straight Edge on the line of the exact size of the top
(When routing with a 5/8″ Template Guide and 1/2″ Bit, the
top will be 1/16″ oversize)
B. Use a Power Grip to hold Straight Edge where it can’t be clamped
5. SAW BUILD-UP AND GLUE TO TOP
A. Sawing approx 1/32″ off both sides of the glued build-up makes
gluing easier and is a must at the inside radius block
B. Clamp accordingly
C. Use 7″ x 7″ block (inside corner radius is 1 1/2″)
D. Mount Sink
E. Fasten substrate to the bottom
F. Machine the cove and glue on the scribe
6. ROUT FINISHED SEAM AND REMOVE GLUE
A. Use the Wavy Base & Bit as in Step 3, but this time rout through the buildup
B. Hook entire Top together as in Step 3
C. The 8″ Indexing Arms are pre-set to hold Straight Edge to remove
1/16″ material. This removes the glue and gets tops to finished
size in one operation
D. Use 1 1/2″ Inside Radius Template to finish the inside corner
7. FINAL DETAILS
A. Cut Cooktop with Sink & Cooktop Cutout Template
B. Rout rabbet for cove splash
C. Rout profile on sink
D. Rout required edge detail
E. Glue cove splash to deck
F. Sand and/or polish as required
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