Worktop join problems - Something wrong with setup.

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Help! I'm doing the worktops on my kitchen extension and something is wrong with my setup.

I've done loads of practices and every one comes out with a gap on the radius of the join. You can see what I mean in these pics ==>

This is happening consistently and I'm sure I'm doing it correctly. It's a good de-walt router and a transtools jig. Router has a 30mm guide bush and the bits are 12.7mm as supplied with the jig. It is doing this with each of the bits (there are 4 supplied with the jig).

I am cutting from left to right with the worktop in the correct orientation so as not to break out the good face on the exit. I'm doing 5 x 8mm passes with the router pulled against the near edge of the slot with the final pass pushed to the far edge of the slot. I'm being really careful to keep the router square to the jig as I know it's really easy to lean the router when half the jig is unsupported.

I can only think that the jig could be faulty? The male and female cuts are done using opposite sides of the guide slot - perhaps the radius is different on each side of the slot?

Alternatively could there be something wrong with the setup of the router? The guide bush seems to be properly round and the bit seems to be central to the naked eye but hard to tell. I can't see any adjustments that would influence this.

I can't progress with the kitchen until this is sorted and the wife is getting very tetchy after 5 weeks of no kitchen! Any suggestions appreciated!
 
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Shouldn’t be able to move the router in the jig slot? Except to follow it .Are you clamping all tight before cut.
 
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Thanks Foxhole, yes I should have added that it is all clamped tight. There is fraction of a mm play in the slot. My understanding is that plunge cuts are done with router pulled towards me (ie the near edge of the slot) and the final trim cut pushed away from me (ie the far edge of the slot).

Cheers

Mike
 
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I only ever pull towards slot , easy to tip router slightly if pushed .
 
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