INProfile 3

The magazine for all Trend Users

3 ISS

UE

INProfile

Routingwith the CRT/MK2Techniques of table routing

Dovetailingwith the DJ300For construction of drawers

Dust extractionThe new Trend T30 extractor

AUTUMN 99

Furniturefocus

Masking joint lines

Latestnew products

A balanced act..

..router cutters manufactured and tested to

meet the Holz BG standard for design,

safety and performance.

www.trend-uk.com

0800 487363

Along with quality products and reliableservice, part of Trend’s tradition hasalways been to provide the customerwith informative and instructionalliterature to enable the reader toachieve the full potential of theirproducts.INProfile is part of that tradition,sharing the knowledge and experience ofTrend’s technical staff, demonstratorsand dealers, along with the commentsfrom both professional and amateurwoodworkers and tradespeople.In the third edition of INProfile we haveagain covered many of the latest newproducts.I hope this information and theaccompanying features will keep youinformed, not only of what is new in theTrend range, but in the ever developingfield of routing technology.

John PerkinsEditor

Editor John Perkins

Technical advisorsMiles Davey Neil McMillan Tom Rogers Jim Phillips

Design/layout Tracy Highland Emma Hughes Neal Martinez

Illustrators Annette Kelly Dave ScammelLazerlines

Contributors Emrys Owen Gordon Warr

PhotographyPhotoworks Matthew Shepherd

Trend Machinery &Cutting Tools Ltd FREEPOST Unit 6 Odhams Trading EstateWatford EnglandWD2 5TR

All Trend products areavailable through anetwork of retailers.Please call our freephonenumber for your neareststockist.

Freephone: 0800 4TREND (0800 487363) Fax: 01923 [email protected] www.trend-uk.com1999 Published by Trend Machineryand Cutting Tools Ltd. All rightsreserved. No part of this publicationmay be reproduced, stored ortransmitted in any form without priorpermission. Our policy of continuousimprovements means that

specifications may change withoutnotice. Trend Machinery and

Cutting Tools Ltdcannot be held

liable for anymaterialrenderedunusable, or forany form ofconsequentialloss.

16 On-Site 3An introduction to the newCOMBI 65 Worktop Jig

18 Drawer onTraditionDrawer construction using theDJ300 Dovetail Jig

22 Just a TrimAn insight into the range ofTrimming Cutters and theirapplications

24 Straight and TrueFeatures and operations ofthe versatile Clamp Guiderange

27 The New UnibaseA preview of the newUniversal Circular Sub-base

28 The Trend T30ExtractorNeil McMillan explains theuses of this new Wet andDry Workshop Extractor

30 Routing CoursesA case study and national guide to sponsored routingcourses around the UK

in thisissue

4 New TrendCraftsmanRouter TableA look at the updated designand new features of the CRTMK2

8 Latest SnappyproductsA brief explanation of theSnappy system and new linesnow available

10 Frame and PanelDoor ConstructionA guide through the stages ofmaking frame and panel doors

13 Carving into theFutureThe Router Carver system

14 Furniture Focus 3Alternative ways to maskundesireable joint lines

15 Spiral CuttersAn insight into the benefits tobe gained from using SpiralCutters

router table for thecraftsman MK2

This Autumn we launch thelatest version of the CRTMK2 Craftsman’s RouterTable. Table Top

An improved cast aluminium, heavily ribbed tabletop ensures adequate rigidity and stability. Itprovides a flat, low friction working surface.

The CRT MK2 router table is designedfor use with all popular routers. Forsetting up, the router is bolted to arigid steel plate which is then bolted tothe underside of the table. Fouralternative plates to suit specific routermakes/models are available and to bespecified when ordering the table, thusenabling the corner plate to besupplied to suit your existing or newrouter. This system allows the routerto be quickly removed for hand heldoperations and avoids the problem ofadjusting a surface mounted plate to lieflat and level with the table surface.

ExtensionsSteel extension tables are fitted at both endsto provide extra support when routing longlengths of timber.

Floor StandAn optional rigid floor stand is now available,designed to support the CRT MK2 table at aconvenient and safe working height. Thepressed steel stand bolts permanently to thetable legs and can be fitted with a front doorand side panels (available separately) to forma useful storage cabinet.

InsertsThree alternative inserts are

supplied as standard toallow the table aperture to

be altered to suit the cutterdiameter. The plastic insertsare a secure press fit in the

aperture recess.

Plunge BarFor precise adjustment and ease of operation, it isadvisable to fit a fine adjuster or Plunge Bar to therouter. While the adjuster is ideal for making fineprecision adjustments to the cutting depth, thePlunge Bar, used in conjunction with the routersdepth stop, simplifies the vertical adjustment ofthe router. Trend Plunge Bars can be fitted toboth the T5 and T9 routers, but alternative modelsare also available to suit most popular routers.

Following on from the success of theoriginal router table, the new CRTMK2 with many new and improved

features built into it, is specifically aimed athelping the woodworker attain a greaterdegree of accuracy and versatility from hisrouter.

Why a Router Table?For many routing operations it is easier,more accurate and safer to use a portablerouter inverted beneath a rigid machiningtable. In this way, many of the problems ofclamping and holding the workpiece areovercome, the work being supported on thetable, leaving both hands free to guide itacross the cutter.

The use of a routing table also introduces awider range of operations. For instance edgeplaning, rebating and other basicwoodworking operations are quicker andeasier to set up. Also the possibilities of using much larger diameter cutters, offersendless opportunities for cabinet making,joint making, moulding and profiling. We takea look at some of the improved features andapplications of this router table. IP

Autumn 1999

Autumn 1999 5

BackfenceTo allow easy and accurateadjustment, the backfence slidesin v-grooves cast into thealuminium table top and can beset to precise measurementsagainst a graduated scale.

GuardTo minimise the risk of finger contactwith the cutter and waste materialbeing thrown up into the operatorseyes, a clear plastic guard is fitted thatautomatically rides over the materialas it is fed across the cutter. Byreducing the open area around thecutter, the guard also increases theefficiency of the dust extraction portin the rear of the backfence. Theguard is fitted using a quick releasepivot pin to allow easy removal forcleaning and maintenance.

Planing FenceBy setting the planing fence proud of the backfencecheeks, planing or moulding operations that removematerial across the full face of the workpiece can be made.As the material is removed, the exposed face of the woodis supported against the adjustable planing fence.

No-Volt Release SwitchThis provides a quick on and off facility for therouter. It also prevents the router from startingup without warning after an unintentionalinterruption to the power supply. The routerpower lead is plugged into the switch, which inturn is plugged into a normal power socket.

6 INProfile Autumn 1999

Curved WorkCurved and straight workpieces can betrimmed or moulded to a templatewhich is mounted on the workpiece.The cutter height is adjusted to allowthe bearing to run along the template.For these operations, the table shouldbe fitted with the optional clear plasticguard and a lead-in pin. The pin allowsthe work to be supported whilst beinggently fed into the cutter.

Dust ExtractionA vacuum extractor can be connected to the dustextraction port on the rear of the backfence. Ashort length of extraction hose with alarge 58mm diameter is now availablefor this purpose allowing the fullefficiency of the extractor to be used.The 1200 watt motor and large capacity wastecontainer of the Trend T30A extractor make it idealfor dust free operation of the CRT MK2 router table.

Spring Pressure ClampsTo prevent the workpiece rising as it is fed

across the cutter, a set of two optional holddown spring pressure clamps are available.

These bolt onto the fence and are fullyadjustable to suit smaller workpieces thatcannot be held safely or securely by hand.

Tenon Push BlockA tenoning push block is fitted to thebackfence to allow the rail end to becut against the side flutes of thecutter rather than the less effectivebottom flutes. The push blockincorporates a clamp to hold the railvertically against the fence.

Routing operations

on the CRT MK2

Edge PlaningWhen edge planing, the planing fence is

adjusted proud of the out-feed fence face.As a general guide, the maximum depth ofcut when planing should not exceed 2mm.

MouldingDecorative moulding operationsusing all styles and sizes of cutterscan be carried out on the CRT MK2.When moulding panel edges, cuttingtenons or carrying out otheroperations with the timber heldvertically against the backfence, theoptional vertical routing supportprevents the bottom of theworkpiece moving awayfrom the fence andprovides betterguarding of theexposed cutter.

GroovingGrooves cut on the face of the workpiece

can be routed with extra safety by using theflip over cutter guard. After setting up

the cutter and checking that theguard lifts freely, the work is fed

across the cutter, held tight againstboth the table and the in and out feed facesof the back fence. Once the workpiece hascleared the cutter the guard drops back to

cover it.

Always use apushstick, keepingyour fingers wellclear of the cutter.Never allow yourfingers to be incontact with the partof the workpiece thatis passing over thecutter, (guardretracted for clarity).

!

Safety First

RebatingRebates can be cut against

the backfence using astraight two flute cutter.

Autumn 1999

Metric ForstnersHigh quality forged andground carbon steelshort forstner bits foruse with the SnappyQuick Chuck. They willdrill clean accurate andoverlapping holes. Theyhave an overall length of

86mm and areoffered in 13 sizes(SNAP/FS/10 etc).

Forstner SetA boxed set of fiveSnappy forstnerbits. Diameters15mm, 20mm, 25mm,30mm and 35mm(SNAP/FS1/SET).

The Snappy range has proved to be successful with Tradesmen,DIYers and Woodworkers. The range has been extended to includeForstners, Flat Bits and Tungsten Carbide Drill Countersinks. Wetake a look at these and how the system works.

1. The Snappy systemstarts with the QuickChuck. This is fittedinto a standard 3/8 inchkey or keyless chuck.Six flats on the shanksensure preciselocation.

2. Snappy bits or anydirect drive 1/4 inchhex bits will then ‘snap’in effortlessly and willnot release until thesprung loaded outersleeve is retracted.

3. A sprung loadedouter sleeve makes iteasy to removeattachments. Just pullit back to release tool.

Using the Snappy System

Pat

ent

No.

5,39

8,94

6

Ball Bearinglocates innarrow neck ofSnappy shanks

HOW DOES THE QUICKCHUCK WORK?

Outerretracting

sleeve is sprungloaded to

release toolsQuick Chuck shankhas 6 flats for morepositive location instandard three jawchuck or keyless chuck

Recessed to allowadjustment of drilllength in Snappydrill countersinks

Compression spring

‘Its all about this....’Snappy tool shanks have a 1/4 inchhexagon shape with a relievedneck to locate in the Quick Chuck.

New extralong QuickChucksTwo new extralong chucks, 3 inchand 6 inch inlength with asmaller 18mmdiameter head togive ease of access,are now available.These will acceptSnappy and inserttype bits and canbe fitted to the Quick Chuck or directly into a drill chuck.

Look for this logo onyour tool packaging!

8 Autumn 1999

MetricFlat BitsAn economical bit forcutting quick holes intimber. They have152mm overall lengthwith a centre point, backtapered cutting edge andground chip breakers.17 sizes are offered(SNAP/FB/8 etc).

Autumn 1999

Depth StopsAdjustable depth stopsto fit Snappy drillcountersinks. Twosizes are offered, 3/8inch diameter drill (forSNAP/CS/4-10) and 1/2inch diameter (forSNAP/CS/12).

Tungsten Carbidetipped versions of thepopular Snappy drillcountersinks with anadjustable drill are nowavailable. These toolscan be used in abrasivematerials such aslaminated chipboard orMDF. They produce pilothole drill sizes from 5/64 inch to

9/64 inch andscrewhead/plugholes of 3/8 inch or1/2 inch(SNAP/CS/4TC,etc.)

5 Piece TCTCountersink SetSet of five Snappy TCTdrill countersinks(SNAP/CSTC/SET).

Flat Bit SetThree piece set comprising a 16mm,19mm and 25mm diameter Snappy flatbit (SNAP/FB1/SET).

TCT DrillCountersinks

Also av

ailab

le Sna

ppy P

lugm

aker

s,Sna

ppy T

wist D

rills

and

Hinge

Dril

l Bit

Guide

s

DID YOU

KNOW........that if you have any tool with this 1/4" hex drive

design, you can use it with a Snappy Chuck.

Making frame and panel doorsusing the router is now anaccepted and common

practice for many professionalwoodworkers. For the homecraftsman it used to be expensive asthere was a need for a heavy dutyrouter, router table and 12.7mm shankcutters. However, with the addition tothe Craft Range of 1/4 inch and 8mmshank profile scribing cutters, routerpower and the cost of professionaltooling is no longer a consideration.These profile scribers are nowavailable in three styles: Flat Classic,Straight Bevel or Ogee Panel Profileand can be used in conjunction withvarious shaped panel raisers. Suchtools with smaller shanks are ideal foruse with the Trend T5 router fitted inthe CRT MK2 router table or withother routers above 850 watts.

Frames and PanelsFor strength, profile scribed joints relyon a tongue cut by the scribing cutterto form a tenon. This tenon engagesinto the panel groove that is cut alongthe inside edge of the door rails andstiles. By reassembling the cuttercomponents, both parts of the jointcan be routed to produce a highdegree of accuracy.

Cutting Profile ScribedJointsIt is general practice when cuttingprofile scribed joints to cut the railend tenon and scribed moulding first,otherwise the bearing guide may dropinto the groove routed when makingthe profile mould.

Setting out and cutting thematerials to size:� First decide on the overall size ofthe door by measuring the cabinetdoor opening.� Decide on the width of the stilesand rails. Remember by making thebottom rail slightly wider than thetop rail and stiles, the door will lookbetter balanced.� Plane the frame timber to an equalthickness, between 18mm and 22mm.� Calculate the length of the top andbottom rails. This will equal thewidth of the door minus twice thewidth of the stiles plus twice thedepth of the panel groove (example420mm - (2 x 52mm) + (2x12mm) = 340mm rail length). Cut the railsexactly to this length leaving the endssquare.� Cut the stiles 20mm to 30mmoverlength, the door length can beset out as the doors are glued up, anyexcess being trimmed off later.� Decorative curved edge top railsare cut to length in the same way,only the width of the rail will differ.� Cut several pieces of similar sizetimber for use as test pieces.� Mark the face side and edge oneach piece.

Cutting the Scribed RailEndsThe profile scribing cutter consists ofa threaded arbor with lock nut,moulding cutter, a grooving cutterand a guide bearing. There are alsothree copper shims and a steelwasher. The cutter is assembledready for cutting a scribe when it

leaves Trend and easy to followassembly diagrams for changing itsmode are supplied. In order toreduce stress on the cutter, turn oneof the cutters so that they are at 90°to each other.

Mount the cutter in the router andset the cutter height to give a topquirk depth of no less than 1.5mm.When cutting, the rail ends must berun against the backfence with the railat right angles to it. Use a steel ruleto adjust the fence so that the face ofthe bearing is aligned with the face ofthe fence. Also check that the fence isparallel to the mitre fence groove onthe table.To hold the rail square to the fence, itis advisable to make up a slidingworkholder incorporating a securemeans of clamping the timber.

10 INProfile Autumn 1999

frame & paneldoor construction

made easyProfile scribed frame joints can now be producedeconomically by the amateur or DIY woodworker

by John Perkins

Autumn 1999

As a decorative feature, a wide moulded rebate is generally used to form a ‘raised field’. The thickness at theedge of the panel will need to be afraction less than 4mm to form a slidingfit in the groove.

Panel Raising CuttersThere are two designs ofpanel raising cutters forthis purpose - horizontalor vertical, both types arebest suited to use in arouter table. The mouldshould be cut in a series of 3 to 4passes adjusting the cutter for eachpass until the full depth is reached onthe final one.

Mount a test piece in the workholderface side up with the end against thefence and a backing piece (spelchblock) of the same thickness behindit to prevent breakout. Beforestarting the router, check that theguard and cutter are secure.

Switch on and pass the rail endacross the cutter keeping theworkpiece flat to the table. Turn thewood around and repeat the cut onthe other end.

Cutting the Edge ProfileWith the router collet held by thespindle lock, use a spanner to loosenthe nut and remove the cutters andbearing from the arbor.Reassemble the cutter fitting themoulding cutter first, followed byshims and the grooving cutter. Fitthe other shim and guide bearingbefore fitting the steelwasher and nut. Checkthat the nut is tightenedfirmly, but avoid turningthe arbor in the collet.

Using the scribed end, lay the railface down on the table and adjustthe height of the cutter to align thegrooving cutter against the tenon andthe moulding profile cutter againstthe quirk.

Start the router and run the edge of atest piece across the cutter.Assemble the joint and check that thefront and rear faces are flush, if not,adjust the cutter height and cut a newtest piece.Check that the joint is a good slidingfit. If not, partially disassemble thecutter and remove or add one of theshims. Reassemble and cut a new testpiece and check the fit.

Making the PanelPanels can either be cut from sheetmaterial or made up from solid timber.The width of the panel will be thesame dimension as the rail length,including the tenon length at each end.The length will be equal to the fullheight of the door, minus the width ofthe top and bottom rails, plus twicethe tenon length.In both cases, deduct 2mm to allow forclearance and on solid timber panels,deduct a further 2mm across thewidth (i.e. across the grain) to allowfor movement.

Cutting Flat PanelsUse sheet material 4mm to 6mm thick.With material over 4mm, a rebate willneed to be cut around the edge on therear face to leave a finished thicknessof 4mm.

Solid panels are generally made up oftwo or more boards glued edge toedge. For normal purposes use timberplaned to a finished thickness of 12 to15mm. Glue the edges together,alternating the grain direction on each.When dry, plane and sand the faces flatand cut the panel to size. The edgewill now need to be rebated to fit intothe panel groove.

Glued panel finished toconsistent thickness

Grooved depth9.5mm

Gap for expansion of panel

11

table with the profilescribingcutterassembled formachining the rail andstile edges. Remove the fenceand fit the clear plastic profiling topguard and lead-in pin. Fit the railinto the workholder and rest it flat onthe table. Switch the router on andfeed the work into the cutter, startingwith the lead-in section of theworkholder against the lead-in pin. Itwill be necessary to cut the profile tothe full depth in one pass. Thereforeadjust your feed rate to allow wasteto clear and keep the stress on thecutter as minimal as possible.

AssemblyBefore gluing the joints, assemblethe frame and panel dry. Finish allsurfaces that cannot be sandedeasily after assembly and have sashcramps and soft packings (to preventthe cramps marking the wood) readyto hand. The panels should not beglued into the groove, but be pinnedwith a brass panel pin at the top andbottom.Assemble the door using the cramps

Curved Top RailsTop and bottom rails can be madewith a curved inner edge, grooved andmoulded to take the door panel. Forthis the rail will need to be cut fromwider material with the curved edgeshaped and squared before cutting theprofile.

To cut the curved edge, mark out theshape on the template material (6mmMDF or plastic). Cut the curve with ajigsaw and finish true and square.Leave extra length at each end toallow a bearing guided cutter to enterand leave the curved face smoothly.

Cut the scribed profile at each end ofthe rail. Make up a workholder asshown, using the template to positionthe rail. Fit the rail into theworkholder and draw along thecurved edge. Remove the rail and cutthe curve, leaving no more than 3mmwaste material on the waste side ofthe line. Cut along the curve with ajigsaw.Mount the rail in the workholder anduse a bearing guided flush trimmingcutter to trim the curved face flush tothe template.With the router disconnected fromthe power source, set up the router

to pull the joints tight. Wipe away anyexcess glue and check that the doorlies flat and square before leaving todry. If the door is to be given a clearfinish, ensure that no traces of glueare left on the surface. IP

FREE BOOKLET

All profile scribers and panel cuttersare supplied with a 64 pageinstruction booklet which featuresthe construction of frame and panelcabinet doors.

Routing GuideThis pocket book is a260 pagecompilation of the popularseries of Trend’s A6 routing bookletsincluding the ‘How to make a Frame & Panel Cabinet Door’booklet shown above. The book also includes sections on:� Cutter & Collet Care� Routing - A Guide to Getting Started� Routing Techniques for Doll’s House Mouldings� 30 Routing Techniques for Tradesmen and Home Improvers

by Matt Shepherd

Achieve impressiveresults with the use ofTrend’s unique RouterCarver system.

The Router Carver enablesanybody, irrelevant of skill, toachieve variable depth carvings

on any flat surface such as drawersand door panels. The carving systemworks by using an adjustable V-Groove cutter whichhas a 45° aluminiumguide cone.

Using special MDF templates, thecutter is plunged into slots of varyingwidths that control the rise and fall ofthe cutter into the workpiece. Theprocess of carving takes only a fewminutes to complete leaving a designof which any craftsman wouldbe proud. A large range ofstyles are available and with theClassic and Royal styles, you cancontinue the theme throughouta number of furniture items.Remember that you don’tnecessarily have to use thecomplete design, sometimes ‘lessis more’. You can even integratedesigns together to give aunique appearance.

OperationFirst fix the template frame eitherwith G cramps or pinned to a battenjig holding the workpiece.

Select the first of your templates,(there could be up to four in total).Fit the first template into the frameand plunge the cutter in the widersection of each slot. Do not lock off

the router but keep a firm downwardpressure, moving along the slot. Thecutter will automatically rise and fall.Always run through the cut twice toensure a clean and complete groove.

Once all the shapes in the templatehave been routed, it is then removed,rotated or inverted and placed backinto the frame and routed again. Thisis repeated so that each slot is usedup to four times.

When completed the workpiece isimmediately ready for finishing.

To help the carving stand out, stain theworkpiece before carving, highlightingthe end result. IP

13Autumn 1999 INProfile

carving into the future

Butt jointing has never been themost attractive or effectiveway of fixing one square piece

of wood to another. The natural andinevitable expansion and contractionof timber will always distort a buttjoint leaving an irregular line.One way of overcoming such aproblem is to exaggerate the jointby creating a mould or profile

along the joint line helping to disguiseany overhang, bowing, wavy ordamaged edges and make the jointlook consistent. Here are just a fewexamples showing how this can beachieved. IP

An example of a typicalbutt joint exposing anunattractive glue line.Any timber movementwould be immediatelyhighlighted. Such a jointnever looks finished.

14 INProfile

by Tom Rogers 33furniturefocusTom Rogers outlines ways ofhiding undesirable joint lines.

A roundedoverhang on thehorizontal sectionusing a staffbead/nosing cutter9/3 as a moulding.

A core boxprofile using a8/20 sunk beadcutter.

A multi corebox profileusing a 8/30bead cutter.

The new Trendbearing guided V-groovetrimmer 46/85.

A 33/60 arbor,SLK slotterand a B280bearing toprovide a5mm by 6mmdeep groove.

The new Trend bearingguided V-groove trimmerref. 46/85 is specificallydesigned for improving thelook of a butt joint. It willtrim the horizontalsection at the same timeas creating the V-groove.

Bearing GuidesAny of the bearing guidedoptions can be used oncurved or shaped joints asthe bearing automaticallyfollows the vertical section.

Straight fluted Tungsten Carbidetipped cutters are certainly themost popular type of cutter

used by router users. Improvementsin design, materials and manufacturingtechnology over the years hasenabled these cutters to cut amultitude of abrasive manmadematerials.

With certain applications, theimpacting action of straight flutedcutters as the tool rotates can causefibres to pick up and this results infeathering on veneers and softwoods.Also when feeding fast they can causethe chips to choke up in the cutgrooves, limiting cutting efficiency andthis reflects in the finish.

But, with the arrival of the spiral orhelical shaped fluting which ismachined from solid carbide rods orhigh speed steel, a number ofadvantages appeared, especially forthe large operators with CNCequipment. But even those usinghand routers are now choosing tobenefit from the slicing “scissor typeaction” of helical fluting.This slicingaction imparts an even load on therouter and reduces vibration, as thereis always a cutting edge in contactwith the material.

The design of spiral tooling enablesfaster feed rates, up to 10 metres aminute depending on the cuttingdepth. The helical geometry ofspirals vary to suit differentapplications of the industry. Thereare three basic types:

Up-cut spirals with righthand helixThis type of fluting lifts the chips inan upward direction away from thecutting area, thus preventing clogging.Although this is an advantage, someform of dust extraction is necessary.

Burning when plunge cutting is all buteliminated and drilling with therouter set at a lower speed, becomesan attractive proposition.

On laminated boards there may besome surface feathering which adown-cut tool would prevent. Theupwards action of the up-cut maycause the workpiece to rise and goodclamping is recommended.

Down-cut spirals withleft hand helixWith “down-cuts”, feed speed isa little restricted but featheringis virtually eliminated and thefinish of cut is first rate. For thisreason, such tooling is oftenchosen when machining boardsfaced with veneers, laminates orfoils.

Combination up anddown-cut spiralsWhen boards are faced on bothsides, the combination spiralcomes into its own. If therouter is grooving or trimmingveneer edgings, the finish isguaranteed to have a clean cutedge on both faces. Inoperation, the upper down-cutpart of the spiral severs thegrain on the top surface of theboard and the lower up-cutsevers the grain on theunderside.

When deciding on the choice ofcutter, the extra cost of usingspiral cutters should beconsidered. First check to seewhether your standard TCcutters have been regularlyhoned to bring them back nearto the original edge.A tendency to feather edge canalso be avoided by scoring apre-cut line prior to routing thegroove. IP

whyspiral cutters?

Jim Phillips gives aninsight into the benefitsof using spiral cutters.

by Jim Phillips

Down-cut spirals give a cleansharp edge but compact thewaste in the mortise.

15INProfile

Up-cut spirals remove thewaste, but leave a slightlyragged edge.

16 INProfile Autumn 1999

on-siteTo obtain close fitting joints when fittingkitchen worktops, a good router and welldesigned jig are essential. Trend’s new Combi65 jig provides the perfection expected byboth kitchen fitters and their customers.

3. Setting up the JigThree aluminium bushes aresupplied for positioning the jig.These are fitted into holes in the jig,one being used to set the cut lengthto suit 600, 640 or 650mm wideworktops.

When joining postformedworktops, the use ofaluminium jointing strips

does not create the same appeal as acontinuous surface for eitherappearance or hygiene.But traditionally, only expensivekitchens had joints as perfect as this.Now the option for perfect fittingjoints is open to all kitchen fitters andeven DIYers, who, using the TrendCombi 65 jig, can rout these jointseconomically on site.

Basic RequirementsTo produce a neat corner joint bothpieces of the worktop need to havean edge routed to an exact shape tofit together perfectly. The Trend jigenables this to be done accurately.The jig itself has an aperture thatguides the router (fitted with a 30mmguide bush) to cut both faces of thejoint. The router must have a 1/2 inchcollet and at least 1300 watts power.Here we will take you through thebasic steps to make a perfect cornerjoint. IP

1. Guide Bush & Cutter The guide bush, when fitted to therouter, must be concentric with thecutter, otherwise a poor jointwould be created. To obtainconcentricity with certain makes ofrouter, a sub-base will be needed.This is fitted to the base of therouter and aligned using a ‘line-uppin’.

2. Fitting a Guide BushWhen using the Trend T9 router,the system for ensuringconcentricity is built into the basedesign. This has an inner plate ontowhich the guide bush is mounted.When concentric, a 1/2 inch(12.7mm) diameter x 2 inch(50mm) long cutter can then befitted.

by Miles Davey

3

4. Female CutTwo more of the bushes are locatedalong the edge of the jig to butt upagainst the postformed edge.Depending on whether the joint is aleft or right hand joint, the laminatesurface may be facing up or down.The jig is held securely to theworktop with two clamps. Therouting operation is then made inthree or four passes depending onthe thickness of the worktop.

Cutters to useA 12.7mm (1/2 inch)diameter long reachcutter is required forcutting the joint.Conventional brazedtipped cutters reference3/83D or C153 can beused. Alternatively areplaceable tipped toolreference RT/11 offeringincreased economy andproductivity.

6. ConnectorWith the two worktops now cut,slide them together face down. Theworktops can now have the recessescut for the connection bolts. Aminimum of two bolts are requiredper joint, positioned at least 150mmfrom either end. The exact positionswill be governed by the supports ofthe carcass as access will be requiredto tighten the bolts. The recessesshould be cut to a depth so that thecentre line of the connector is alignedwith the centre line of the worktop.

7. Biscuit JointingThe strength of the joint can beincreased by biscuit jointing at regularintervals along the chipboard core.This can be carried out with therouter fitted with the 342 Biscuit Jointcutter set. Use large No. 20 biscuitsand fit at least four biscuits per joint.

8.Assembly TipsIn some kitchens, assembly maybe difficult without an extrapair of hands. Apply PVA glueto the slots, place biscuits inposition and spread glue evenlyalong each edge. It is also agood idea to run a siliconebead along the top edge toprevent any moisture fromentering the joint when pulledtight. Once the joint istogether, ensure that the top surfaceis flush. Finally, tighten the boltconnectors with a 10mm spanner andremove any excess glue or silicone.

17Autumn 1999 INProfile

5. Male CutTwo of the aluminium bushes arenow re-positioned and the jig laidacross the second worktop for themale cut. Again, the laminate of theworktop may be facing up or down.The router is guided against the lefthand side of the aperture as before.

The use of traditional dovetailsstill remains the strongest andmost attractive method of

drawer construction. Traditionalmethods of hand-cutting dovetailsrequire time, skill and patience. Witha router and a dovetail jig, joints fordrawer fronts can be easily cut withonly minimal setting-up to achieveprofessional results. I take the DJ300through it’s paces to produce avariety of drawer styles.

First of all when cutting dovetailjoints, it is imperative that the timberis finished square and the sides are ofequal width and length. The spacing

of the tails and pins isautomatically set by thespacing of the fingers of thetemplates. The width of thedrawer sides and front shouldideally be a multiple of thetemplate’s spacing to ensurethere are no partial dovetailscreated. Adjustments can beeasily made to ensure that thehalf pins at each end appearequal.The endstops have offset edges toautomatically position the drawer sideone full spacing to the right or left ofthe drawer front so that the tails andpins are cut at the same time.

18 Autumn 1999

draweron

traditionDovetailing drawers

with the DJ300 Jig

by Emrys Owen

Having worked for the forestrycommission for 35 years, Emrys nowruns his own business makingfurniture and restoring antiques.

Adjust templatepositionAdjust the lock nuts toalign the back of thetemplate slots with the15mm line on the settinggauge.

Setting GaugeTo assist setting-up the jig eachtime with different templates, asetting gauge can be made andused. This consists of arectangular piece of MDF orplywood with the offset linesdrawn down each edge.Alternatively keep a jointproduced with each template anduse them for setting-up.

2.

Clamping the timberFollowing the sequence markedon each piece, position the firstdrawer side beneath the frontbar on the left hand side of thejig and tighten the clamp.Position the drawer front underthe top bar, butting it against thedrawer side and the edge guide,and clamp it firmly. Slacken thedrawer side and raise it untilflush with the top surface of thedrawer front and re-clamp.

Autumn 1999

Ideal Timber WidthsFor the 1/2 inch dovetail template the finger

‘pitch’ is 21.5mm therefore the timber widths

should ideally be multiples of 21.5mm (e.g. 3

tails = 64.5mm, 4 tails = 86mm etc). For the

1/4 inch template the pitch is 11.3mm

therefore the material widths are 3 tails =

44mm and 4 tails = 45mm etc. A simple lookup

table is provided in the instruction manual.

Clamp the gauge in position withthe setting line aligned with theinside edge of the first slot in thetemplate. Remove the templateand slide the edge guide alonguntil it is against the gauge.Tighten the locking screw andrepeat this procedure at theother end of the jig. Remove thesetting gauge and retain it forfuture use.

Fit the guide bush to the base of the routerand the dovetail cutter in the collet. (Use the

large guide bush ref. GB157 for 1/2 inchdovetails, and the small diameter guide bush

ref. GB774 for 1/4 inch dovetails). The heightof the 1/2 inch dovetail cutter should be setapproximately 17mm above the router base

and the 1/4 inch dovetail cutter approximately11mm. The exact height can be obtained by

making a test joint and adjusting it to suit thetightness of joint required.

Marking out the ComponentsHaving cut the timber to size, it is essential to set outand mark the order of assembly so that each pieceis fitted into the jig in the correct order and theright way up. When joining the drawer frontto the sides, the dovetail joint on oneside of the drawer is cut on the left-hand side of the jig and the otheris cut on the right. Rememberthat the joints are cut with theinside faces of the drawer facingup (drawer front) and outwards(drawer side).

Front

Rightside

Setting-up the JigEnsure that the jig is assembled andsecured to a work surface as shownin the instruction manual. Beforecontinuing check that the correctedge guides are fitted to suit thetemplate being used. There are 4 setsof guides, each set consisting of a left-hand and right-hand plate to suit eachtemplate. Extra guides are providedshould rebated drawer fronts berequired.

Carry out the following steps for 1/2inch dovetails; steps one to three arecarried out only once on initial set-up:

1.

4.

19

3.

Use a slotter mounted on an arbor to cutto a depth of 4 to 5mm to produce thegroove for the drawer bottom. This canbe easier to do with it set-up in a router

table. Alternatively a 4 mmstraight fluted cutter can

be used using asidefence portably.

When fitting drawers intoenclosed cabinets, make theback lower to avoid airpressure behind the drawermaking it difficult to close

Drawer back fitted tosides with lappeddovetails (as cut forfront), or rebatedjoints and glued orpinned to plywoodbottom

Routing the JointStart the router and rout across thefront edge, feeding the router fromright to left (this will prevent breakout along the front edge).And then from left to right move therouter in between the fingers of thetemplate. Check that all waste hasbeen removed before removing theworkpiece or making any adjustmentto the jig. Repeat the procedure forthe opposite side taking care tofollow the correct procedure.

Never attempt to lift the routerupwards - you may catch thetemplate with the cutter. And alwayswait for the cutter to stop rotatingbefore sliding it away from thetemplate. IP

Rebated DovetailsRebated dovetails are cut in two stages. Firstthe drawer front is rebated using a straightcutter, guided by the router sidefence or fittedin a router table, or by using a rebate cutter.The second stage, using the DJ300 dovetail jig isthe same as the cutting sequence for flush sideddrawers, but using edge guide set No.2 for 1/2inch dovetails and No.4 for 1/4 inch dovetails.

All the operations showncan be repeated for 1/4inch dovetails using the 1/4inch template, differentedge guides, the 1/4 inchdovetail cutter and thesmaller guide bush.

1/2 inch dovetail withrebated front

1/4 inch dovetailwith rebated front

Feeddirection

Clearanceangle

Cuttingangle

Rake angleor hook

Reliefof tip

Radial reliefof body

Gulletor flute

Rotationof cutter

Material (woodchip, swarf or wooddust) removed byeach cutting edge per revolution

1. Cutters should conform to aprecise geometric design, anduse high quality materialscomplying with specific DINspecifications to ensure a safetool with a high degree ofprecision and balance.

2. The thickness of chip limit mustbe a cutting edge projection of1.1mm over the total length ofthe cutting profile. This is tolimit the injury to any part ofthe body, that may come incontact with the rotating tool.

3. Restricted maximum chipclearance width, including theregrinding range as a functionof the cutting flight circle. Thisis intended to limit thekickback energy to a minimumand to prevent injury to theuser.

4. Maximum rotation speed isdetermined according to thetool dimension and materialswith the help of a computerprogram. The tests includedynamic balance and overspeedtesting to twice maximum RPM.

Drawerfront

Drawer side fixed to front withlapped or rebated dovetails

Drawer bottom(4 to 6mm plywood)set into groove routedinto sides and front

Safety when using power tools and cutting tools is always ofparamount importance. We briefly explain how and why routercutters should meet the HOLZ BG international standard toensure they have a safe and approved design before using them.In past years, the reporting of large numbers of accidents, has led to the establishment ofinternational standards for the design and manufacture of tools for the woodworking andplastics industries. The standard is governed by the Holz BG institute in Munich whererigorous testing is carried out and certificates issued to manufacturers complying withcertain rigid rules.

These rules state specific standards for a router cutter’s design, the materials used,and tolerances in manufacture. The design must also be of a safety style toreduce risk of injury and possibility of kickback.

Our professional range of router cutters have been designedand manufactured to the Holz BG standard for a number ofyears. Confirmation of this can be found on the shank and on thepackaging of each product. Claims by other manufacturers thattheir router cutters have the Holz BG form, e.g. cutters with a roundbody, should not be automatically accepted as having passed theHolz BG test. Cutters conforming to the Holz BG test have aspecific test number. Our test numbers are as follows:

safety innumbers

Timber ThicknessTo achieve a well fitting joint, thedepth of the pins must equal thethickness of the tails. This is governedby the position of the template whichcan be adjusted.Although each pair of sides should beof a uniform thickness, the actualthickness is not crucial. For the 1/2inch template use material between11mm and 25mm thick. For the 1/4inch template use material between8mm and 12mm (a packing piece fittedunder the front clamping bar will beneeded with the smaller thickness).

Cutting a Test PieceBefore cutting dovetail joints on theactual workpiece, cut one or severaltest pieces so that the correct cutterheight, position of the edge guides andtemplate position can be confirmed.

Drawer front can bemoulded with a suitablemoulding cutter.

BG Rules:

BG-TEST159-001

BG-TEST159-002

21Autumn 1999 INProfile

Most of the furniture that wecome into contact withtoday, in the home or at

work, is made of faced sheetmaterials. That is, a veneer or facing

of real wood, plastic, metal foil orresin impregnated paper glued

to a base or core of MDF, plywood,chipboard or other stable material.

Whichever facing or laminate is used,it will need to be trimmed flush

with the edges of the basematerial. This is where therouter and tungsten carbidetipped trimming cutters come

into their own. Light andportable, the router can be taken to

the ‘job’, or inexpensively built intolaminating machines and presses

where the board can be faced,edged and trimmed, in onecontinuous process. It is not

only veneers and laminates thatcan be trimmed in this way, self-

guiding trimming cutters can also beused for producing and finishingtemplate and pattern work, savingboth time and cost over traditionalhand finishing methods.

Veneer and LaminateTrimming Bonding To produce a smooth square edge, theedges of the board itself must be cuttrue and finished square and smooth.The reason for this is that thetrimming cutter is guided by a flushguide bearing that follows the boardedge, reproducing the exact contour,straight or curved. All trimming andprofiling cutters follow this simplebasic concept, however they do varyin some aspects. In particular, thenumber of cutting edges and thecutter profile. Bearing guidedtrimming and profiling cutters arefitted with guide bearings that aremarginally oversize to minimise theeffects of surface scoring and to avoidany cut-back of the veneer edge to

produce a sharp, square corner when jointing or facing the trimmed edge.

AdhesivesWhichever adhesive is used to bondthe facing to the base material, twoimportant points must be observed.The first is that the adhesive must beallowed to dry or set thoroughlybefore trimming, if not, the adhesive islikely to ‘gum up’ the bearing.Bearings cannot be cleaned and re-greased and will therefore needreplacing. The second point to beobserved is that any excess adhesiveleft on the guide face (i.e. the boardedge), will catch the guide bearing,leaving an irregular edge to the facing.

Trimming CutterVariations - Triple FluteGround with three TCT cutting edges,this cutter will produce an extremelyclean sharp edge on all materials.Ideal for plywood, veneer andlaminate, these should generally beused as a finishing cutter. Two sizesare available, the larger being fittedwith twin guided bearings forprolonged life.

Economy Trim CuttersMade from solid carbide, economytrim cutters are intended for use onshort runs only. Two versions areavailable, 90° flush trim with a self

22

Just a trimThe quality of finish required when trimming veneersand laminates can only be achieved by using precisionrouter cutters designed specifically for this purpose.

Template Profiling

Autumn 1999

23

guiding tip and a 90° - 60° cutter thatwill flush cut or bevel simply byadjusting the cutting depth. Thesecutters have fairly short cutting edgelengths (10mm and 6mm respectively).

Combi CuttersThese cutters perform two functions:First they trim the overlay flush, thenthey can bevel at various angles.Some types have a bottom cut to trimthe upstand and others have bearingsfor self-guiding work.

Pierce and Trim CuttersCombination pierce and trim cuttersare used for cutting internal apertureswhen fitting basins, hobs and otherinset units. These cutters aredesigned to drill through and cutaround the laminate facing, followingthe outline of a pre-cut aperturebeneath. The laminate is applied overthe whole top and the adhesiveallowed to dry, before the laminate iscut away. When applying laminates itis common practice to apply abalancing veneer or laminate to thereverse face to prevent bowing.Apertures can then be cut in a similarfashion as before, but using a twincutting edge pierce and trim cutter tocut through both the face laminateand balancer at the same time.

Template ProfilingCuttersIntended for template work, thesetrimming cutters offer a more directalternative to guide bushes. Whenusing these cutters the template ismade to the exact size required.Templates must be secured to thematerial firmly by clamping, pining orgluing. Hot melt glue will hold welland can be easily removed afterwards.For small projects, double-sidedadhesive tape can be used. Bothtemplate profiling cutters with shankmounted bearings and trimmingcutters with their tip mountedbearing can be used for templatework, either fitted in an invertedrouter table, overhead router orhandheld.

When using the handheld method,ensure that the workpiece is safelysecured to the bench. IP

minimachThe portable clampingbed powered by aworkshop vacuumextractor.

� Fast, simple obstruction freeclamping when routing,sanding and sawing.

� Powered by a workshopvacuum extractor.

� Holds sheet materials up to1220mm x 1220mm down to95mm x 95mm.

� Can be fitted to anyworkbench or secured to anyflat surface.

NEW APPLICATION

When trimming laminates, it willlessen the stress and wear onyour cutter if you limit theoverhang to no more than 3mm,removing any excess beforetrimming. A bearingguided overlaptrimmer ref. 46/19can be used forthis purpose.

Combination Cutters

Ideal for shaping smallitems to a template.

Now includes 2.5 metres oftemplate gasket for templatecopying. Using vacuum power,the gasket enables the workpieceto be held down onto a templatewhich in turn is held securely bythe Minimach.

Extra seal available:MMACH/SEAL/1 ____£1.95

NEW LOWERPRICE

£65.00 + VAT

How many times have we allstruggled when cutting largesheet material into smaller

pieces, a batten in one hand, twocramps in the other and packingpieces so that we don’t mark thesurface!

Of course that was the bad old days,now we have Clamp Guides, BenchClamps and Pro Tracks.

All three are designed to make life alot easier on-site, at home or in theworkshop. Made up with an

aluminium extrusion fitted with onesliding and one fixed jaw, they areinfinitely adjustable along their lengthand lock tight with a flick of a toggle.Once pressure is applied, the work isheld firmly, the simple cam lockoffering two clamping pressures -tight and tighter.

Clamp GuidesFor use as a straight edge or sashcramp, the Clamp Guide locks ontoany square edged, parallel sidedmaterial, to act as a router or sawguide. Alternatively they can be usedfor clamping several pieces togetherfor machining or to supplement othercramps when gluing up. Available inthree sizes 610mm (24 inches),915mm (36 inches) and 1270mm (50 inches) between the jaws, the flat

profile of theClamp Guide (15mm

high) minimises any risk ofobstructing the power tool

during the cutting operation.

The Clamp Guide can also be used asa general purpose straight edge formarking out and in particular whenscoring with a craft knife as the guidecan be clamped to the workpiece or acutting board beneath it, allowingyour fingers to be kept away from theguide edge and knife blade.In the workshop you will soon find the Clamp Guide indispensable, as a supplementary long fence on band saws and saw tables, as a planing stopon a workbench and for a widevariety of other uses.

Using the Clamp GuideSimply mark off the position of thecut, allowing for the base of therouter or saw (that is the distancefrom the cutter or sawblade to theedge of the baseplate). Position theclamp and slide the jaws against theedges of the material. Lock the toggle to the first position and check with a

straight& true

A straight edge clamped across theworkpiece is common practice forguiding the router, but even suchbasic technology can be improved on.

Sliding Jaw

LockingLever

INProfile Autumn 199924

by Gordon Warr

New Jaw ExtensionAn extension jaw enablesthe Clamp Guide, BenchClamp and Pro Track toclamp onto curved edgessuch as kitchen worktops.Ref. CG/03 ___£3.95

25

try square that the guide is square tothe edge of the workpiece. Set thetoggle to the second position if youwish to tighten it. Soft facings aresupplied with the Clamp Guide toprotect edges of delicate workpieces.

Bench ClampsSimilar in operation to the ClampGuide, the Bench Clamp is designedto hold a flat workpiece to a worksurface leaving the face of theworkpiece unobstructed. The BenchClamp is fitted with fixed and slidingjaws on both sides of the aluminiumextrusions. One set is used to clampit to a flat parallel edged worksurface, while the top jaws clamp tothe workpiece. The lack of anyprotrusion above the surface allows

total free access when freehandrouting, sanding, hand planing and for many other machining andfinishing operations.The Bench Clamp is available in threesizes with capacities, between thejaws, of 460mm (18 inches), 915mm(36 inches) and 1270mm (50 inches).Clamped to vertical rails fitted to thefront or end of a workbench oracross the legs, the Bench Clamp canalso be used to hold workpiecesvertically, ideal when squaring ordoweling the ends of panels.

Although generally used in pairs, theBench Clamp can be used on its ownto hold small items. Again soft facingsare supplied to avoid marking theedge of delicate work, while curved

jaw blocks can be easily cut and fittedto hold curved or irregular edges.The Bench Clamp can be fitted tomost square edge surfaces includingfolding benches such as theWorkmate®.

The Bench Clamp can be used inmany similar ways to the ClampGuide and can be used in conjunctionwith it, using the Bench Clamp tohold the workpiece to the bench andthe Clamp Guide to guide the powertool across it.

Autumn 1999 INProfile

Clamp Guide Pro TrackThis is the most sophisticated ofthese three guide systems. Althoughsimilar in construction and materialsto the other guides, the Pro Track hasa 125mm (5 inch) wide extrusion tomake it extremely rigid and isavailable in jaw opening capacities of610mm (24 inches), 1220mm (48inches) and 2440mm (96 inches).Both edges of the Pro Trackextrusion have a T-slot that engagesthe machined edge of one or twoalternative carriage plates, allowingthem to slide along the guide edgeover the face of the workpiece.

One plate is designed to take arouter, the other a circular saw. Thisallows straight cuts to be madeacross the work face with no risk ofwandering away from the guide edge.

Power Tool MountingThe carriage plates are made of nylonmachined along one edge to fit intothe T-slot as well as to extend overthe top face of the extrusion. Asecond T-slot in the top face of theextrusion accepts a tee-bolt andthumb knob, fitted through the plateextension to stop the plate andpower tool from tipping. Thisarrangement allows open frames aswell as flush panels to be cut orrouted, the power tool beingsupported on the plate as it is fedacross the workpiece.

Both carriage plates are 19mm (3/4inch) thick, the router plate having acircular recess of 190mm (7.5 inches)large enough to take most popularrouters. To locate the router, theplate is pre-drilled to suit the tablemounting holes in the router base onthe Trend T9 & T5 routers. For otherrouters, both the router and carriageplate can be drilled to takecountersunk machine screws(ensuring that the screw heads donot protrude below the plate).Alternatively, the router plate recesshas a 30mm diameter centre hole

that takes a 30mm outside diameterguide bush. With this size guide bushfitted, the router can be simplydropped into the recess, allowing theguide bush to both centre and locateit allowing the normal down force tohold it in place while routing.

The carriage plate for the sawmeasures approximately 355 x240mm (14 x 9.5 inches) with thesame thickness as the router platebut no recess. The saw can be eitherfitted to the edge of the plate bydrilling both and using countersunkscrews, or by cutting a central slotwith a router cutter wide enough totake the blade and blade guard(always fit the saw in such a way thatthe blade guard continues to operateas before). When fitting jigsaws, asmall hole can be drilled to take theblade and the base plate eitherscrewed or clamped (with homemade clamps) to the plate.

Length StopsIn order to limit the length orposition of the cut, stop blocks to fitthe Pro Track are available as anoptional accessory. These simplyengage in the tracks T-slot and can belocked with a T-nut as on the carriageplates. IP

Autumn 199926

the new

UNIBASEGuide bushes and templates using thenew UNIBASE universal sub-base.by Neil McMillan

Guide BushesA guide bush consists of a projecting

ring of a specific diameter, fitted to a

mounting flange. Fitted to the base

plate of the router, the guide bush ring

projects beneath the base by

approximately 5mm. The cutter is then

free to revolve concentrically within the

ring, as the outside edge of the ring

follows the template contour. Due to

the difference in diameter between the

guide bush ring and the cutter, an offset

or margin must be allowed for when

setting and cutting out the template.

The use of templates and guidebushes opens up a hugenumber of possibilities for

router users. Cutters with a bearingguide on the end can only be used on

the edge of aworkpiece.However aguide bushplaces theguiding methodabove thecutter, allowingthe workpiecesto be routedeither on theedge or in thecentre.

Different diameter guide bushes areneeded to suit different applicationsand router cutters. Here lies theproblem. Most router manufacturersdo not offer a wide range of guidebushes and each size and method offitting differs from one manufacturerto another. Often guide bushes for aparticular machine can be difficult tosource and various jigs require aspecific size of guide bush.

The new UNIBASE offers a solution forowners of most makes of router. Madefrom injection moulding plastic, it isformed with a range of hole positionsto allow it to be fitted to all popularmakes of router, using the bolts orscrews provided. It is also suppliedwith two line-up pins with shank sizesfor both imperial and metric collets anda 16mm line-up bush. These allow theUNIBASE, fitted with the guide, to bealigned concentric to the cutter.

Guide bushes ranging from 10mm to32mm in 2mm increments and a 40mmbush are offered to give flexibility in thechoice of router cutters for specificapplications. Please note, the UNIBASEis not required for Trend routers asbushes fit direct into the router base.Additionally, the Trend T9 has anintegral method of adjustment built intothe base.

TemplatesTemplates can be made from plywood,MDF or plastic. The material should behardwearing, stable and easy tomachine.

The thickness of template must besufficient to prevent the template ringfrom touching the workpiece, but notso thick as to cause a loss of cuttingdepth. A thickness of 6mm or 1/4 inchis ideal. IP

27

Autumn 1999

by Neil McMillan

the new

T30

Vacuum extractors for use withpowertools are designed tocapture large and fine particles

produced at source. This ensures thatparticles do not become airbornewhere they can be inhaled or caughtin the eye.

The new T30A extractor capturesparticles by filtering the air through apaper bag, and finer dust particles arethen removed by a cartridge filter.A pre-filter option can also be fittedthat extends the life and performanceof the cartridge filter.

A 1200 watt bypass motor providesthe power to the unit and an autostart facility allows direct connectionof any 240 volt powertool up to 2000watts. With the extractor set toautomatic, the extractor will start upwhen the powertool is switched on.When switched off, the extractor willrun on for a further six seconds to

clear the hose.This auto featuresaves unnecessaryswitching on andoff, while the extra long cable (7.8m)avoids the need for an extension lead!

The extractor has a generous fivemetre x 36mm diameter flexible hosethat has an integral swivel connectorthat fits Trend and other makes ofrouters. This extra length provesideal for power sanding. An optionallarger 58mm diameter hose enablesdirect connection to router tablesand stationery machines, offering anincrease in performance due to thelarger volume throughput.

The T30AF version should be usedwhen routing fine dust as itincorporates as standard a 0.5 microncartridge filter and a nylon pre-filter.A paper filter bag should still be used.A T30A can be upgraded to a T30AF

With growing concerns about the damageto health from inhaling dust when usingpowertools, we highlight the merits of thenew T30 vacuum extractor.

Furniture Brush(Optional)

58mm HoseAdaptor

(Optional)

Cloth Pre-filter(Optional)

Nylon Wet and Dry Pre-filter(Standard with T30AF)

Floor Cleaning Kit(Standard)

workshop extractor

by replacing the standard cartridgefilter with a 0.5 micron cartridgefilter (ref.T30/5) and adding anylon pre filter. (ref.T30/3). IP

Specifications� 1200 watt bypass motor with two fans

� Large 34 litre dry container capacity

� Power tool take off with auto start for up to2000 watts, and with a 6 second delay

� Extra long hose 5 metre x 36mm diameter

� Extra long 7.8 metre power cable

� Five castors for manoeuvrability and stability

29Autumn 1999 INProfile

No Foam Filter(Optional)

Paper Filter Bag(Standard)

58mm x 1.5metre Hose(Optional)

0.5 Micron MicroCartridge Filter

(Standard with T30AF)

12 Micron Cartridge Filter(Standard with T30A)

36mm x 5m Hose(Standard)

Floor KitThe T30A is supplied with a standard floorcleaning kit to allow the vacuum cleaner toclean up the work area and workshop. Thefloor kit comes with three types of brushesfor flooring, carpets and vacuuming fluids. Acrevice tool, upholstery tool and powertool adaptor are also included.

Wet & Dry use The T30A container has a 34 Litre drycapacity and a 25 Litre wet capacity. Fornormal dry use a paper filter bag, and thestandard 12 micron cartridge filter shouldbe fitted (filter filtrates particles above 12micron in size). A cloth pre-filter (ref.T30/2) can be purchased separately which

prolongs the life of the cartridge filter. Forwet use the extractor is fitted with a floatthat prevents water from entering themachine. The paper bag and cartridgefilter must be removed. A no-foam filteraccessory (ref.T30/4) is available whichprevents foaming in the machine (ifrequired). A nylon pre-filter (ref.T30/3) isalso available that is washable and can beused for both wet and dry use.

ApplicationsThe T30A is ideal for use with manyrouter tables where the large optional58mm diameter hose can be fitted intothe aperture of the backfence.

For obstruction free clamping the Minimach and the T30A areideal. By switching on the vacuum and turning the vacuumcontrol tap to the open position, the MINIMACH clamps itself tothe workbench and will then hold the workpiece down securelyfor sanding, routing and planing operations.

The T30A vacuum extractor can also be used in conjunctionwith portable circular saws.

Our second routing coursecase study took us to theone day beginners course

set in the beautiful west countryvillage of Martock, Somerset, thehome of Yandles Woodworking.

As well as being spoilt by anextensively stocked showroomincluding hand tools, powertools and arts and crafts, you’llbe impressed by the array ofworldwide exotic timbers,thrilled by the works of art inthe china, craft and doll’s housegalleries and tempted by theexquisite home-made food in

the restaurant.

The routing course is situated nextto the sawmill in their course centre.As with any course that involves theuse of machinery, the first stagecovered health and safety issues withemphasis on ‘always unplug yourrouter before making anycorrections or alterations’ the ruleso often told, yet rarely actioned.Once we were clear about the safetyaspects we dealt with care andmaintenance of routers and cutters,in particular, preventativemaintenance.

The next stage, dealt with familiarityof the component parts andaccessories of the router, theirfunctions and the logical implicationsof misuse or overload.

For the rest of the morning, wefollowed the lecturersdemonstrations with basic routingtechniques, like sidefence work toproduce grooves, rebates, steppedmoulds and mortises, the benefits ofthe clamp guides and bench clamps,the use of guide bushes andtemplates and the advantages andaccuracy of bearing guided cutters.Following lunch, we watcheddemonstrations on the CraftsmanRouter Table, the DJ300 Dovetail Jigand the Router Carver, all of whichallowed time for practice periods.

Lastly, we were able to test some ofthe techniques we had attemptedearlier in the day by producing abread board:Taking a square section of timber,this was held down to the benchusing double-sided tape and thecentre marked to locate the positionfor the trammel.

Then, using a two flute straightcutter we cut through our boards instages to produce the completecircle.

Next we slid the router in along the

trammel bar by 30mm then changed the cutter for a radius or core cutterto cut our crumb groove.Finally, using an ovolo cutter, weprofiled the outside edge tocomplete our board.

A little time is left at the end of thecourse when the lecturer can dealwith particular requirements of thestudents.

The course covered safety and basicrouting techniques in sufficient detail,provided plenty of hands-on andenabled the students to go homewith a bread board they had madethemselves. I thought the coursewas very good value for money and Ihighly recommend it! IP

Course Details:One day basic through to advancedcourses available. Includes hand-heldtechniques and table routing.

Course Price __________£55

Hurst Works, Martock, SomersetTA12 6JU Tel: 01935 822207Contacts: Ann Pain or Carol BulmerLecturers: Gordon Mitchell, JohnParslow & John Stevons

Yandlesshowroom

Dolls Housegallery

INProfile sent Tom Rogers along to Yandlesto review their one day routing course.

30 Autumn 1999

Forming basicbread boardshape

Completed bread board

Yandlescourse review

routingcoursesTrend sponsor a number of one and two dayrouting courses around the UK. For your nearestcourse centre please refer to the list below.

Course centres situated around the UK

Our web site gives you details on our latest products,news, events and technicalassistance. In addition to theinformation from our latestcatalogue available on-line, itfeatures:

� Product manuals, instruction leaflets,test reviews and other free literatureto download.

� A section dedicated to getting startedwith a router, as well as information fortradesmen and other professionalusers.

� A facility to locate your nearest Trend stockist in the UK and full details of our overseas distribution network.

� Answers to frequently asked questions about our routers, cutters and jigs.

www.trendm.co.ukEmail: [email protected]

Get the latest update oncourses from our web site

Bookmark our site in your web browser and make a regular visit. You canalso email us for any further information or help you need.

www.trend-uk.com

AUSTIN EAMESPlas Acton Precinct Pandy LaneWrexham Clwyd LL11 2UBTel: 01978 261095 Contacts: Peter or Richard Eames

CRAFT SUPPLIES ACADEMYThe Mill Millers Dale Nr BuxtonDerbyshire SK17 8SNTel: 01298 871636 Contact: Eve Middleton

EDINBURGH’S TELFORD COLLEGECrewe Toll Edinburgh EH4 2NZTel: 0131 315 7229Contacts: Keith Swann or Gregor Allen

JOE GREENERS WOODWORKING CENTREValley Street North DarlingtonCo. Durham DL1 1PZTel: Freephone 0800 7312145 Contacts: Joe or Andy Greener

NEATH COLLEGEDwr-y-felin Road Neath WalesSA10 7RF Tel: 01639 634271 Contacts: Dylan Wyn James or Wyn Pritchard

OAKLANDS COLLEGESchool of ConstructionSt Peters Road St Albans Herts AL1 3RX Tel: 01727 737213 Contact: Jeanne O’Reilly

ROY SUTTON14 St Georges Avenue Herne Bay Kent CT6 8JUTel: 01227 372500Contact: Roy Sutton

SPEEDWELL TOOL CO62-70 Meadow Street Preston PR1 1SU Tel: 01772 252951Contact: Monica Parker

THE ROUTING CENTREBluebell Industrial Estate Dublin 12Republic of Ireland Tel: 00 3531 4566604Contacts: Jim or Eamonn O’Neill

WOODCRAFT TRAINING50 West Street Isleham Nr ElyCambridgeshire CB7 5SBTel: 01638 780978 Contact: Mike Humphrey

YANDLES OF MARTOCKHurst Works Martock Somerset TA12 6JUTel: 01935 822207 Contacts: Ann Pain or Carol Bulmer

Take the plunge

www.trend-uk.com

0800 487363

Quick and Easy height adjustment for the Trend

T5 & T9 Routers