The primary installation method is a two-step process. It creates a cavity with a shelf onto which the box’s load beam collar rests. The lower part of the cavity houses the bottom of the box. To ease the routing of these cavities the routing system includes jigs that simplify the routing process. These jigs allow the routing to take place without the need to adjust the depth of the router bit.
The system consists of three jigs - base, bottom, and top. The base jig is the primary positioning jig that locates the other jigs.
The bottom jig routs the center cavity for the bottom of the box. It nests within the base jig when in use. Finally, the top jig routs the shelf onto which the box rests. This jig sits on top of the base jig and has overhanging ends that position it on the base jig. It is the thickness of this jig that sets the correct depth of the router bit.
In addition to the complete routing system the jigs can be purchased as a set or individually making it simple to replace any part of the system when needed.
All jigs are made from glass filled polycarbonate so they are strong, durable, and relatively inexpensive.
Base jig is the foundation of the routing system. Ensures correct placement of the routing system. Soft rubber pad on the bottom prevents damage and minimizes movement of the jig.
Features a number of markings on the upper surface to assist in the correct placement on a board. Made from glass filled polycarbonate, making them inexpensive and durable.
The base jig is the primary jig, locates the system on the surfboard, and it isn't removed until the routing process is complete. Designed to make the process of locating the system on the surfboard as simple as possible. Small windows extend through each end of the jig that make it easier to position the jig on the shapers mark.
Used in conjunction with a pair of centerlines extending the length of the jig, and down inside the central cutout in the jig. There are two centerlines. One that represents the actual center of the box and runs down the center of the jig. Used when installing a center box. The side box centerline positions the side boxes, this centerline represents the inner face of the fin slot.
Marks on the jig help alignment when installing side boxes. An arrow and the word "Rail" indicates the positioning of the jig, relative to the rail of the surfboard. There are two shapers mark windows, so that they work for both sides of the board. The back window on the jig is always used to position the jig on the shapers mark. The base jig has a soft rubber pad on the bottom to protect the surfboard, and also to prevent the jig from moving. The bottom of the base jig is also shaped to make it easier to place in deep double concaves, and for easier handling. Accomplished with a 45º chamfer around the bottom edge of the jig. Made from glass filled polycarbonate.
Placed within the inner cutout of the base jig, the bottom jig to routs the cavity for the bottom of the box. No positioning required, drop it into the base jig and then rout the cavity. For this operation the router bit is set to the deepest depth.
Like the base jig, this jig has a rail side indicator to help orient the jig. Made from glass filled polycarbonate.
This jig is used to rout the shelf onto which the box rests. After routing the bottom cavity, the bottom jig is removed and the top jig is placed on top of the base jig. The jig is self positioning on top of the base jig with locators that lock the jig in place.
The jig automatically adjusts the router bit depth. Like the base jig, this jig has a rail side indicator to help position the jig. Made from glass filled polycarbonate.
Utilizes a router bit with an upper bearing. This bearing runs against the inner surface of the routing jigs, generating the correct outline.
The router bit has a 6mm (1/4") shank. 9.5mm (3/8") cutting diameter. 19mm (3/4") cutting depth. Utilizes a 13mm (1/2") diameter bearing.
A hex key is provided with the routing system. This key is used to adjust the grub screws before installation of the boxes. Features a full-size Allen wrench housed within the plastic, so it is very effective. Also used when installing fins in the system.
WARNING: do not over tighten screws as this can lead to stripping!
The final piece of the install system is a depth gauge that is used to set the depth of the router bit. It is used as shown in the illustration below. There are two separate depth settings on the gauge, STANDARD (circular notch on the side) for a normal install, and CONCAVE (triangular notch on the side) for installations in double concaves, this depth is 1/32" deeper than the normal install.
The side with a notch is always up to get one of the two depths - CIRCULAR = STANDARD and TRIANGULAR = CONCAVE. The flat edge is placed on the router base, as shown, and the depth is adjusted till the cutters touch the gauge.
The routing system also comes with a printed install guide detailing the entire process. The STANDARD Install Guide covers the basic install process for normal boards. A separate guide is provided for low density EPS installation in the form of the 1ROUT Install Guide. A lot of information on how to correctly install the system is provided, with variations for different construction techniques.
All of the information available in the various install guides can also be found on this site. Along with a lot of other information about the installation process.
More details here - INSTALL DETAILS