PreparationĪ GEARBOX install is very simple and only requires our routing system, hex key, die cut tape, boxes, and a router that you provide. A measurement of roughly 31mm (1 7/32” ) from the base of the router to the tip of the cutters on the router bit can be used as a starting point! This results in a cavity that is slightly deeper than the depth of the box when installed in a deep concave. NOTE: for installation into deep double concaves it is advisable to set the bit a little deeper in order to allow the box to be fully below the bottom surface, at the lowest point of the concave.
It is a good idea to do a test run on a scrap of foam to ensure that everything is correct before proceeding. A better install can be achieved by always having the box be slightly below the lip of the routed cavity. Router Bit SetupĪlternatively, a box can be placed on the bottom of the jig, then adjust the bit until it is slightly above the top of the upper surface of the load beam collar.
The depth gauge is placed on the bottom of the router base with the appropriate notch above the router bit for the desired depth - CIRCULAR Notch = STANDARD and TRIANGULAR Notch = CONCAVE, as shown in the illustration above. See EXTRAS section at the end of this page for more details on the gauge. Depending on the severity of the concave the depth might need to be adjusted from the one provided. The concave depth is deeper due to the base router jig tending to bridge the concave, the goal is to have the flange of the box be slightly below the lowest point of the install cavity. 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 DEPTH GAUGE supplied with the routing system is used to setup the depth of the router bit relative to the bottom of the router base. As a time saver the EPS Install can be used as it requires less routing, but it is slightly more expensive due to the increased cost for the HD foam block! The Standard Install should be used for any polyurethane or EPS install where the EPS is 1.5# density or greater.
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