inprofile 1

The magazine for all Trend Users

r o u t i n g t e c h n o l o g y

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trend

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INProfile

SpirallingsuccessTurning on the Trend Routerlathe

RoutingworkshopMake your own bench

BiscuitjointingModern construction techniques

SPECIALOFFERS

LATESTPRODUCTS

NEWS& VIEWS

WINTER 97

Trend WAVEFORM®Sawblades are the productof extensive research into the needs of today’sprofessional and industrial sawblade users.

Designed to out-perform any other TCTsawblades, they are manufactured using thelatest technologies and materials to offeroutstanding value.

WAVEFORM®Sawblades are available fromyour nearest Trend stockist. Full details of thecomplete range are in our new Catalogue outnow.

THE NEW FORCE

IN SAWBLADES

The chrome alloyed steel plateis lazer cut, tempered and

roller-tensioned to ensure thehighest tolerances on lateral

run-out and flatness

Highly polished bladebody prevents resin

build-upFully re-sharpenable precision

ground tungsten carbide tips foraccurate cutting of material and

extended sawblade life

Expansion slots for heatdissipation and noise

reduction

Reamed bore for perfectfit onto saw spindle

Automated brazing oftungsten carbide tips ensuresthe strongest bond between

the body and the tip

http://www.trend-uk.com/en/UK/productsubgroup1/228/Waveform_Sawblades.html

Winter 1997 INProfile

Editor John Perkins Technical advisors John Tigg Neil McMillan Tom Rogers Miles Davey Design/layout Tracy Highland Emma Hughes Maggie Robinson Illustrations Annette Kelly Dave Scammel Geoff Wood Contributors Jim Phillips Geoff Wood Neil McMillan Front cover photography Andy Carhill & John Perkins at Photoworks

Trend Machinery & Cutting Tools Ltd Freepost Penfold Works Imperial Way Watford Herts WD2 4WDFreephone: 0800 4 TREND (0800 487363) Tel: 01923 249911 Fax: 01923 236879Email: [email protected] WWW: http://www.trendm.co.uk

1997 Published by Trend Machinery and Cutting Tools Ltd. All rights reserved. No part of this publication may be reproduced, stored or transmitted in any form without prior permission. Our policy of continuous improvements means that specifications may change without notice.Trend Machinery and Cutting Tools Ltd cannot be held liable for any material rendered unusable, or for any form of consequential loss.

Welcome to the first issue ofINProfile. Our aim in publishing thismagazine is to provide a linkbetween all users of our products,stockists and Trend, not only toannounce new products but to helpyou get the best from the entireTrend range.Future editions of INProfile willinclude articles on general aspects ofwoodworking as well as routing,techniques and technical information.We would also welcome forinclusion comments, tips, news andviews from readers, stockists andwoodworkersin general.

John PerkinsEditor

in this issue

3

4 Know your RouterGuide to the modern plunge router

5 Know your CutterGuide to the basic range of cutters

6 What is Routing?An introduction to routing

8 New ProductsNew additions to the Trend product range

10 Spiralling SuccessTurning on the Trend Routerlathe

14 Routing into the MillenniumJim Phillips takes us through the development of the router

16 Biscuit JointingAn alternative to traditional joining techniques

20 New Books & VideosLatest additions to the Trend library

21 New CuttersNew additions to the Trend Cutter range

22 Routing WorkshopA dedicated Routing bench

26 On CourseNational guide to Trend routing courses

29 ContemplatingCircle cutting templates for the workshop

http://www.trend-uk.com/

INProfile Winter 1997

Modern plunge routers(such as the Trend T5shown) are designed for

safe handling, easy control andreliability.A smooth sprung plunge actionensures that the cutter enters andwithdraws cleanly and squarely fromthe surface of the work, safelyretracting the cutter above thebaseplate. Cutter installation is

simplified by use of an integralspindle lock, while micro-adjustmentof both the depth gauge and side-fence, ensure precision and accuracywhen routing. An easily accessible,quick action switch allows forsmooth and positive control.Limited only by the experience andinventiveness of the user, with carefulselection of the correct cutter to suita specific application, the plunge

router can be used to produce veryaccurate work to a fine, quality finish.Being simple and functional in itsdesign, a working knowledge inhandling the router is not difficult toattain. A little experience willquickly encourage both amateur andprofessional crafts people to bothintensify and extend the use andscope of routing within their hobbyor occupation.

know your router..

Plunge columns

Fixed side handle

On/off switch

Motor housing

Router base plate

Collet & lock nut

Spindle lock

Cutter depth gauge

Plunge lock/release handle

Three positionturret stop

Depth stop

Side-fence locking knob

Speed control

Driven by a compact high speed motor, the modern electricrouter is a versatile and adaptable power tool, capable ofmachining wood, plastics and aluminium.

4


Always feed the router into thework against the rotation of thecutter. This ensures that the cuttingaction pulls the side fence or guidebearing into the edge of the work ortemplate, preventing it fromwandering and so providing far

greater control. Feeding the cutterinto the work in the oppositedirection (with the rotation of thecutter) may cause the router to runaway from you, reducing the controlyou have over it.

..know your cutters

Tungsten CarbideTungsten carbide tips are used formost general routing applications asthey retain their edge far longerthan High Speed Steel cutters. Theyshould always be used for cuttingand trimming abrasive materialssuch as MDF, chipboard and otherresin bonded materials and can beused equally as well on certainplastics and natural timbers.

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

The Shank is machined to aclose tolerance to match theinternal diameter of thecollet.

The Flange or Fillet is theradiused section between theshank and the cutter body.

Tungsten carbide tips are brazed ontoa steel body before being ground tospecific cutting angles. The correcttip and relief angles are essential toensure optimum performance.

Self-guiding cutters are ground to take aball bearing guide. The bearing is usedto follow the edge of a template, or theedge of the work itself, for trimmingand moulding applications.

Flutes are ground intothe cutter body leavingprecise clearances andrelief angles. Theseclearances prevent wastematerial from packingbetween the cutter andthe face of the wood.

Part of the skill of routing is selecting and using the correct cutterfor the job in hand. To produce a quality finish, cutters must bekept in good condition and be regularly honed.

Feed direction

Radius

Chamfer

Ovolo

Dovetail

A selection oftungsten carbide

tipped cutters fromTrend’s Craft Range

Rebater

Straight

5

6 INProfile Winter 1997

Routing encompasses a widerange of skills, not just inhandling the router itself, but

in using it to its best advantage inconjunction with various, guides, jigsand other ‘routing devices’, as well as

the extensive range of routercutters now available. Routing isalso about innovation in both the

methods and applications to whichthe router is applied and in theaesthetic and technical design

that it is used to create.

The RouterMost woodworkers turning to routinghave some idea and experience of working with power tools.Most householders will haveoccasionally used a jigsaw or electricdrill and will know that power toolscome in a range of power ratings andcapacities - the more power you have,

the faster and harder you can goabout the job - well that’s the

theory anyway! However, as if you arebuying a new car, computer

or washing machine, you willstill want to know just what to

buy to suit you and your pocket.Accordingly, the questions facing thenewcomer to routing are most likelyto be:How much power do I need?, Whatcollet size do I need?, Do I needvariable speed?, Do I need to buy

lots of accessories?, Do I need to buylots of cutters?

Self Assessment! How much power? - This depends onthe type of work that you intend to use the router for.If you are cutting dolls house

mouldings or trimming veneers or

laminates, there is little point in

buying a heavy duty router. It will be

too heavy and clumsy for the

purpose. Conversely, if you are

making doors and window frames,

you would not be able to remove

enough material efficiently without

overloading the motor. This would

cause the cutting speed to drop,

resulting in a poor finish and possible

premature burn-out of the motor and

bearings.

what is

routing?The electric router is nowaccepted, by both amateur andprofessional woodworkers, as anessential tool for the workshop.

Collet CapacityFor many applications thestrength of a cutteroften depends on thediameter of the cuttershank. The thicker thecutter shank, the morewood you can removeand the deeper you can cut on anyone pass, with less risk of the cutterflexing excessively or breaking.Light duty routers are generallysupplied with 6.5mm (1/4”) colletsalthough some models can be fittedwith an optional 8mm collet. Theintroduction of 8mm shanks hasallowed many of the larger diametercutters to be used in light dutyrouters, although particular care mustbe taken when using them and anymanufacturers recommendationsconcerning cutting speed and depthof cut must be closely observed.Most medium and heavy duty routerscan be fitted with alternativediameter collets of 6.35mm (1/4”),9.5mm (3/8”), 12.7mm (1/2”) and8mm diameter, although most aresupplied with only 1/4 inch or both1/4 and 1/2 inch collets. Alternativesize collets are available for mostmakes and models of router. Doremember that small diameter cuttershanks will flex more, with a greaterrisk of breakage under the increasedload from a heavy duty router.

Router Power(746 watts = 1 HP )

Light Duty Routers400-750 Watts

Medium Duty750-1200 Watts

Heavy Duty1200 and above

such as the Trend starter set.Although not all the cutters will beused as frequently as others, this willprovide valuable experience of thebasic range, and in selecting the mostsuitable cutters for specificapplications in the future. IP

remember that small diameter cuttershanks will flex more, with a greaterrisk of breakage under the increasedload from a heavy duty router.

Speed & Variable SpeedRouter spindle speeds are generallygiven as no-load speeds, that is thespeed that the motor spindle isrotating at before the cutter entersthe wood. This is generally between18,000 and 30,000 RPM depending onthe power of the router. Light dutyrouters will have a higher no-loadspeed to help compensate for theirlower power. Most routingoperations using cutters up to 25mmdiameter, should be carried out at themaximum router speed to achieveoptimum cutting efficiency.

Operations involving the use ofcutters over 50mm diameter shouldbe carried out at speeds of between12,000 and 16,000 rpm.Variable speed routers with full wave,load compensated electronics, tend torun smoother and possibly quieterthan single speed machines, resultingin reduced bearing wear andeliminating the initial jolt on start-up.They also accommodate the use oflarge diameter cutters at theirrecommended safe speed.Aluminium and plastics requirerouting at lower speeds to reduceoverheating or melting, preventingproblems such as weld-back, wherebymolten waste material re-formswithin the cut, or the fusion of wasteparticles to the cutter.

Which Accessories?The few guides and accessoriessupplied with the router allow you tocarry out various basic cuttingoperations such as edge trimming,

moulding, and template work.However, to increase the versatility ofyour router it is worth consideringadding further accessories to yourrouting workshop.The range of accessories that can bebought, includes router tables, circleand ellipse cutting jigs and decorative carving, lettering and turningattachments. Proprietary jigs andtemplates are also available for cuttingstair-housings, joining laminated work-tops and cutting dovetail joints.Alternatively many jigs and templatescan be made in the workshop to suityour specific requirements, and jigmaking accessories, such as levers,knobs, threaded inserts and routermounting plates, are readily available.For the newcomer, the array ofrouting accessories is often confusing,but one of the first considerationsshould be an inverted router table toallow the router to be used as astationary, rather than a hand heldmachine. A rigid, easily adjustableinverted router table will provide fargreater accuracy, ease of use andincreased safety for carrying out awide range of routing operations.

Which Cutters? For the beginner, it is certainly notworth buying a large selection ofcutters until you know exactly whichtypes you will use most frequently oruntil you are faced with a specifictask. Various size straight cutters arealways worth having as they servemany more applications than justcutting grooves and rebates. Usedwith angle guides and stepped fences,they can be used for cutting mitres,edge planing and trimming.An economic solution for thebeginner is buy a basic set of cutters

Help


NewBooks & Videos

FREE Booklets

Our range of books andvideos will help you getthe best from your routerand lead you on to moreinnovative and creativewoodworking.See page 20 for moreinformation

r o u t i n g t e c h n o l o g y

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trendtrend

30 PRACTICAL ROUTING TECHNIQUES AROUND THE HOME

ROUTING TECHNIQUES

FOR TRADESMEN & HOME IMPROVERS

BO

OK

/TT

D

BOOKLET

IN A SERIES

30This ‘30 Routing Techniques’ booklet ispacked with practical routing ideas and

techniques for tradesmen and homeimprovers.

This 32 page illustrated booklet will takeyou step by step from setting up yourrouter, to using all the cutters in the TrendStarter set and their correct application.

Router TableTo extend the versatility ofthe router, a router tableshould be the firstconsideration.

7

Biscuit Jointer Blade

This new six wing TCT blade is foruse with all standard biscuit jointingmachines, having a blade diameter of100mm and bore size of 22mm.The new anti-kickback designprovides better cutting control,while the flat scriber tooth formproduces a quality finish.

Ref. BJB/100S £34.95

DMT Diamond Aligner Kit

Sharpen your kitchen and workshopknives to a perfect edge and to theoptimum cutting angle guided by theDMT Aligner. It is availableseparately or as a kit with a 4”diamond whetstone. The kit issupplied with a fabric storage wallet.

Refs.ABG Aligner only £8.46

AKF Aligner kit with 1 stone (fine) £31.50

new products4 piece Cutter Set

A set of four 1/4” shank cuttersaimed at those new to routing isnow available.- 10mm straight flute cutter - 60° V-groove cutter- 8mm bearing guided rounding

over cutter - 12.7mm decorative panelling cutter

Ref. SET/SS6x1/4TC £27.95

A selection of new products now available from your local Trend stockist

Reduction Sleeves

Two further sizes of reductionsleeve have been added to theTrend range, allowing smaller8mm and 6.3mm diameter shankcutters to be used in12.7mm and 8mm collets.

Refs.SLV/0812 £10.55SLV/1408 £7.95

Collets

Two new 8mm collets areavailable to fit the light dutyHitachi routers. One is designedto fit the older FM8* and laterZK2008* routers, the other is foruse in the Hitachi M8(V)** router.

Refs.997526* £8.95302193** £35.50

Mini Collet

A new 3mm collet is availablewhich fits the Elu MOF96(E)and DeWalt DW613, allowing3mm shank miniature cuttersto be used in these routers.

Ref. 53351030 £27.14

DMT Double-sidedDiafold Whetstones

A DMT 4” double-sided diafoldhandle whetstone with two gritcombinations offers dual purposehoning of cutting tools. Availablein extra-fine/fine*, fine/coarse**

and coarse/extra-coarse*** gritcombinations.

Refs.FWEF* £39.95FWFC** £39.95FWCX*** £39.95

INProfile Winter 1997 All prices exclude VAT8

Snappy Screwdriver Bits

Phillips® and Pozidriv® bits for theSnappy Quick Chuck are available insizes 1, 2 and 3 in packs containingthree of the same size or mixed.

Boxed Biscuits

Biscuit dowels are now available inassorted sizes, packed in a convenientrefillable packet. The pack containsthirty of each of the two smaller sizebiscuits No’s 0 and 10 and forty ofthe larger size No 20.

Ref. BSC/MIX/100£4.05

Snappy Set

The revolutionary Snappy QuickChuck is now available in a 19 pieceboxed set containing 7 sizes of drilladaptors complete with drills, 5sizes of countersinks complete withdrills, 3 sizes of centring guides and3 sizes of Pozidriv® screwdriverbits. The kit is supplied in a strongplastic carrying case that is alsoavailable separately*.

Refs.SNAP/KIT/1 £64.95CASE /SNAP/1* £5.95

SNAP/PH/1 or SNAP/PZ/1 £4.50




Refs.

4-piece 3D-Bit Set

Twice as fast at cutting as a normalbit and capable of drilling at an angle,four sizes of the popular 3D-Bits arenow available as a boxed set. Theset contains bits of 15mm, 18mm,20mm and 22mm diameter and issupplied complete with instructionsin a strong plastic case.

Ref. 3D/KIT/2 £59.99


Releasable Cable Ties

Suitable for a multitude of uses,releasable cable ties offer a quickand easy method of securingpower leads for storage or tokeep them safely away from theworking area. Moulded with arelease tab and ratchet, theseblack nylon ties are 250mm longby 7.5mm wide. Will tie a bundlediameter up to 68mm.

CTR/250/10 Pack of 10 £1.95CTR/250/25 Pack of 25 £3.95CTR/250/50 Pack of 50 £6.95

Refs.

DMT Mini Jig

A DMT mini jig is available forsharpening craft knife blades. Foruse with either 8” fine or extra fine whetstones.

Ref. MKF £10.40

All prices exclude VAT 9


The Routerlathe’s appeal foramateur woodworkers lies inits ability to produce turned,

tapered, fluted and barley twist work,quickly and effortlessly, whilerequiring only a basic knowledge ofturning techniques. For theprofessional, the Routerlathe offersan economic, time saving method ofproducing occasional work, either inbatches or as one-off components.

Centre to CentreAs with a conventional lathe, theworkpiece is held between twocentres. The maximum timber lengththat can be used is 930mm and themaximum spiral length that can becut is 630mm. The minimum squaresection that can be used is 26mm andthe maximum 79mm. Fitted to asliding carriage, the router is hand fedalong the workpiece for parallel,tapered or fluted work, or cable fedfor spiral, roping or barley twistoperations.

The ease and creativity afforded by the Trend Routerlathein turning tapered, fluted and barley twist work has appealfor both amateur and professional woodworkers.

spirallingsuccess

turning on the Trend Routerlathe

Tailstock Mounted on a pivoted plate, thethreaded tailstock centre allows theworkpiece to be tightened betweencentres and facilitates the cutting oftapered work.

Router CarriageThe sliding router carriage is slottedto accommodate the most popularrouters. The depth of cut is set usingthe routers own depth gauge andturret stop and adjusting the levellingfeet fitted to the sliding carriage.

10


Cable DriveThe carriage is cable driven allowingboth right and left hand spirals to becut. By disengaging the dividing headpin the headstock can be rotatedfreely for cutting radial beads.

TailstockA continuously

threaded rod andwing nut allows the

workpiece to besecure between

centres.

HeadstockAn alternative

pronged Headstockcentre is used when

fitting pre-turnedwork.

Cable DriveThe drive cable is

clamped to theRouter carriage

when cuttingdecorative spirals

and roping.

CarriageThe cutter height is

initially set using theadjustable feet on the

router carriage.

HeadstockA square cup is fitted to the standardheadstock to accept square sectionmaterial. An alternative four prongcentre is available for use with timberthat has been previously turned‘round’ on a conventional lathe orplaned to a hexagonal section. Theheadstock is rotated by a crankedhandle and incorporates a 24 positiondividing head, for accurately spacingflutes and spirals around theworkpiece.

11


Using the TrendRouterlatheThe Trend Routerlathe is suppliedready assembled, requiring only to befastened to a baseboard or bench topand for the router to be mounted onits sliding carriage.

Fitting the routerThe router is centred over thecarriage cutter aperture preferablyusing the threaded locating points onthe router base. It is important toensure that the router’s power lead isled clear of the lathe and it isadvisable to use a dust extractor.

Preparing the timberOnly close and straight grainedtimber should be used. Avoid woollygrained material and timber that iscracked, split or contains loose knots.

Turning or rounding theworkpiece To ‘round’ a workpiece, the index pinis withdrawn and the cabledisconnected from the carriage.Stops are positioned to limit thecarriage travel to the length of thesection to be turned. Using therouter’s depth gauge and turret stop,the depth of cut is set to allow thework to be cut in steps of no morethan 2mm. Starting from the tailstockend, the router is switched on andallowed to reach full speed. Withpractice, feeding the cutter into andalong the timber will become asmooth continuous movement usingone hand to control the router andthe other to turn the crank. Having

roughly rounded it along its length,The height of the workpiece isadjusted using the pivoted plate, toproduce a taper offset of up to 12mm.

Radial beads and covesDecorative beads and coves are cutusing one or a combination of cutterprofiles.Short dowels for joining sections toturned lengths are also cut in thisway, using a straight cutter. Aftersetting out each bead or cove on therounded workpiece, the carriagestops are positioned to retain therouter in each appropriate positionfor cutting.

Spiralling and flutingSingle or multiple start spirals are cutusing the indexing head. For multiplespirals, divide the 24 index points bythe number of spirals (i.e. 2,3,4,6,8,12or 24). Starting from 1, count off thepoints to the next start position (i.e.24 ÷ 6 = 4. Start at 1 + 4 = 5, 5 + 4= 9 etc. (1,5,9,13,17,21). To ensurethat the correct sequence is followed,note each pin position as it is used.

Cutting through spiralsThrough spirals are cut using a longreach cutter to remove the wastefrom the core of the workpieceleaving a hollow centre. Howevercare must be taken as the short grainleft when cutting through spirals,leaves the finished work fairly fragile.

Flutes and beadsBy using the dividing head, equallyspaced flutes and beads can be cutlengthwise along parallel or taperedwork,V-groove, panel mould, radiusedor straight cutters can be used forthis purpose. Prepare the timbereither round or flat sided, and mountit between centres. Set the carriagestops to define the length of the fluteor bead. Flutes and beads on taperedworkpieces can be cut either parallelto the surface, or run out ( i.e. tobecome shallower ), towards thenarrow end of the leg or spindle. Todo this the flute angle needs to be

CentringPrior to fittingthe timber, pre-drill locationholes for theheadstock andtailstock

TaperingThe pivotedplate is usedwhen cuttingtapered spindlesor flutes

Radial CutsBeads and covescan be plungecut with therouter

TemplateWorkTemplates canbe used for copyor contourrouting

12

altered from the taper angle byadjusting the tailstock centre height.

TemplatesFor copy or contour routing, thecutting depth is controlled by afollower running on the edge of atemplate fitted to the front of theRouterlathe.The design should be first drawn outon squared paper, setting out thecurve or taper of the component andthe position of any radial bead orcove. As the profile relates to thecutter shape, it is often onlynecessary to provide a notch in thetemplate edge to locate the follower.As the cutter is positioned half waybetween the router carriage pivotpoint and the follower, the verticaldepths need to be doubled. Forcomplex designs, it may be easiest tocut two or more simple templatesrather than one complicated one. IP


Routerlathe cutters

Most plunge cutting router cutterscan be used with the Routerlathe,including straight, coves anddecorative moulding cutters. Onlystraight cutters with suitablebottom cut characteristics shouldbe used. Two sets of cutters areavailable from Trend, especiallyselected for use with theRouterlathe. These consist ofseven Tungsten Carbide Tipped(TCT) cutters, or seven similarprofile High Speed Steel (HSS)cutters. Both sets are availablewith either 1/4” or 8mm diametershanks.

Cutter set references SET/RLxTC 1/4” shank SET/RLxTC 8mm shankSET/RLxHSS 1/4” shankSET/RLxHSS 8mm shank

High speed steelcutters from the

seven piece set areideal for making clean

cuts in soft woods.

13

1930’s-40’s The spindle moulder was wellestablished as a heavy duty machinefor the joinery shop, but alreadypeople were realising that for lightwork, it was like using a hammer tocrack a nut. Hence ‘wood engineers’across the developed world started tothink in terms of a hand held moulderwith an adjustable base that wouldallow you to set both the depth andwidth of cut. But it took a group ofengineering firms in South WestGermany, whose forebears were Swissimmigrants, skilled in clock making, todevelop the ‘plunge’ router, featuringretractable spring-loaded columns anda range of guides and jigs to giveversatility to routing operations.

1950’sIt was at this time,Trend came on thescene to bring routing technology tonew heights of achievement. Whennews reached us about the plungerouters produced in Germany and inparticular those of Eugen Lutz KG(Elu), we secured the agency for theirtools in the UK.

Although Elurouters were years ahead

of their rivals,Trend came up withfurther developments following feed-back from UK end users. Trendcarried out in-depth research withinthe UK woodworking trades with aview to upgrading design features tomeet recommendations. Inconsequence, the performance of Elurouters against other competitorsreflected in buoyant UK sales anddomination of the market.As router designs improved it becameclear that the range of router cuttersneeded extending to perform most ofthe jobs formerly done on a spindlemoulder. Trend set about designingand introducing a more extensiverange. The first shank-mountedbearing, self guiding cutters were tomy knowledge, a product of mymicro-workshop.From a range of approximately 50router cutters in 1958,Trend nowoffer tooling with 2000 variations insizes and profiles.

1960’s-70’s We had now forged close links withthe Elu factory and in 1972 became asubsidiary of Eugen Lutz as ‘TrendElu’. Routers were now being madewith more powerful motors inside

compact and resilient plastic bodies.Innovative depth gauges and turretstops were introduced. Accessoriesincluded special jigs and devices togive further scope to routingapplications.Having been recognised for ourauthoritative knowledge of routingtechniques, we were now invited todesign a small dovetail jig to bemarketed world-wide. This was ahighly successful product, and to thisday many thousands are produced byBlack and Decker Ltd in the UK forworldwide distribution.Trend were also the pioneers of dustextraction systems for routers, anddesigned extraction ports for thecomplete Elu range. At this timeTrend also introduced variable speedcontrol units for use with routersanticipating the need for machines torun at slower speeds of 12000/16000RPM when using cutters above 50mmin diameter.

1980’s and 90’sThe popularity of the router acrossthe whole spectrum of thewoodworking trades, was now wellestablished, but in the UK there wasno hand-book on the subject. TheTrend team unearthed all theexperience they had accumulated


Almost every conceivable profilecan be cut with a modern handrouter. But how did the router

develop to what it is today?

routinginto the millennium

by Jim Phillips

A keen woodworker, Jim’senthusiasm for the Router led

him to form Trend in 1955.

14

Recessing HingesAll doors need to be recessed to takehinges and this is a job that can beeasily and quickly carried out using alight duty router. For this I prefer touse the router fitted with a guidebush to follow a simple template.When fitting hinges around 100mmlong, use a 10mm (3/8 inch) diametercutter and 20mm diameter guidebush. This leaves an adequate guidebush margin allowing waste to cleareasily through the base-plate apertureof the router. (Trend ref 3/08 x1/4and GB20).

The hinge template is cut frommedium density fibreboard (MDF) of6.3 mm to 12.7 mm thickness andscrewed to a clamping batten forsecuring to the edge of the door.Measure off the length and width ofthe hinge leaf and set this out, eitherside of a centre line drawn across thetemplate. Allow for the differencebetween the cutter and guide bushdiameters by adding this margin twiceto the leaf length and once to thewidth.To calculate the margin (M) subtractthe cutter diameter (d) from theoutside diameter of the guide bush(D) and divide by two (i.e. 20 - 10 =10 ÷ 2 = 5mm :Therefore the hingeleaf length will be +10mm and width+ 5mm). Take your time in settingout and cutting the template, asthis will be reflected in the finalfinish and fit. As most hinges are

of standard sizes, keep the templatesafe for use on future occasions.Set out the centre line of the hingeposition on the door edge, align itwith the centre line of the templateand clamp the jig to the door.Use the routers depth gauge to setthe depth of cut (i.e. the thickness of the hinge leaf), by standing therouter on a flat board and plungingthe cutter to touch the surface.Adjust the depth stop by inserting thehinge leaf between one of the turretstop screws and the depth gauge rod.Rout the hinge recess by first cuttingin at each end, before removing theremaining, waste, feeding the routeragainst the rotation of the cutter.Finally square the corners of therecess with a sharp chisel. IP

IP


over the years and brought into being ‘Techniques of Routing’. Firstpublished in 1981, fifty thousandcopies were sold during the followingfive years. Updated copies still enjoygood sales, in spite of the many otherbooks on the subject now on offer.

Into the futureThere is no stopping the advance ofthis fascinating tool that is truly a‘Workshop in itself ’.But just where is routing going in theyears ahead?Obviously, today’s trends point toeven more versatile routers in thenear future, with an unlimited rangeof cutters to ‘mould and shape’industry. Maybe, early in the nextmillennium, you will see even furtheradvancements, such as ‘virtual reality’controlled routers! Series woundmotors will be replaced bycontinuously rated brushless ones.Routers will become quieter andmore user friendly, not even a colletspanner to mislay.Finally, I predict new technology willnot demise the router for we willincreasingly need ‘living’ materialsaround us. Natural wood will alwayshold its own in a ‘plastic’ world andthe router will continue to providethe means of producing warm andfriendly shapes in wood.

by Miles Davey

Having trained as a carpenter, Miles turned hisattention to cabinet making before joining theTrend Technical department in 1995.

Over 50,000copies havebeen sold sincethe first edition.

on-sitetechniques for the trade

1.

2.

3.

4.

5.

Templatebeing used forrecessinghinge leaves.

15

Similar in principle to loosetongue and groove joints, biscuitjointing uses ‘biscuits’ or flat

dowels, (also referred to as ‘joiningplates’) in place of a traditionalcontinuous tongue. The biscuits arelocated in matching semi-circular

recesses cut in the meetingfaces of the joint, using a

dedicated ‘biscuit jointer’.Biscuit jointing produces ajoint stronger and moreaccurate thanconventional doweled

joints, leaving a flush andprecise assembled joint line. Bylocating in short stopped recessesrather than a continuous groove,biscuit jointing eliminates any risk ofjoint failure due to the weakness ofthe groove edge, or of the edges

curling. To cut the recesses, thejointer is fitted with a 100mmdiameter blade to match the edgeradius of the biscuits. Fitted withhorizontal and vertical fences,inscribed with registration and centremarks, quick, easy and accuratealignment is possible for cutting thecorresponding recesses in the jointfaces. A graduated depth stop is fittedto determine the depth of the recessin relation to the standard biscuitsizes. Alternatively, where a dedicatedbiscuit jointer is neither viable oreconomical, biscuit jointing canbe successfullycarried out usingthe routerfitted witha bearingguided

grooving cutter (recommendedgrooving cutter 40mm diameter x4mm kerf, (Trend ref. SL/GG).While the router’s depth gauge isused to position the recesses acrossthe joint faces, the depth of cut isdetermined by the guide bearingdiameter, different diameter bearingsbeing substituted to suit each of thestandard biscuit sizes. Using thesmaller diameter cutter (as opposedto the 100mm jointer blade), it isnecessary to feed the router alongthe joint face, leaving a recess or

pocket slightly longer than thebiscuit length. This allows somelateral adjustment for easy

alignment and crampingduring assembly. Biscuit

jointing operations can also becarried out on inverted or overhead

biscuitjointing

Biscuit Jointing offers an efficient andtime-saving alternative to traditionaljointing methods for both solid timberor timber-based sheet material.


by Geoff Wood

Geoff Woods is a furniture designeron domestic and systems officefurniture. Whilst at ConranAssociates he worked on DIY booksfor Mitchell Beezley.

16

table routers, using the table fenceand/or cutter guide bearing todetermine the depth of cut andsetting the cutter height above thetable to centre the recesses acrossthe joint faces.

BiscuitsLaminated and compressed, preferablyfrom beech, the elliptical biscuits arecut with the grain running diagonallyto achieve maximum strength whenthe joint is assembled. Biscuitreinforced joints should be assembledusing a water based adhesive (PVA,

Cascamite etc.) as the waterabsorption of the timber

causes the biscuits toexpand and tighten

in the recesses.When drythe biscuitsretain theirincreased

size, producing astrong rigid joint.Both faces of thebiscuits are embossed

to expose themaximum surface area

and both edges are lightlybevelled to allow easy

insertion. Purpose made gluedispensers are available to ensure thatthe adhesive is applied in the correctquantity to produce a sound andsecure joint when dry. Biscuits mustbe kept in a dry place ideally in aclosed container to keep outmoisture and to keep them clean anddust free.

Timber thicknessThe three sizes of biscuit availablefrom Trend are suitable for materialthickness between 8 and 25mm: No. 0for 8-12mm thick, No.10 for 13-18mm and No.20 for19-25 mm.However, for thickness over 20mmtwo or more biscuits used in tandemshould be considered. When markingout it is recommended that biscuitsshould be set out at between 150mmand 250mm centres and no less than50mm in from the ends of the

workpiece. Where possible biscuitsshould be centred across the jointfaces or spaced equally across themFor thicker timbers, larger biscuits areavailable from specialist sources, asare thinner biscuits of 3mm thickness.

Preparation and settingup the routerIt is essential that all faces are cut andfinished true and square before therecesses are set out. Always mark theface sides and edges for easyreference prior to setting out therecesses on each face, cutting fromeach pair of marked faces or edges, toensure that the surfaces are flushwhen assembled. This reduces theamount of finishing required andavoids problems when joiningveneered or laminated surfaces.When gluing solid timber, alternatethe direction of the growth rings tominimise cupping across the glued-upboard and the amount of finalfinishing required.Select the appropriate diameterbearing for the required biscuit sizeand assemble the cutter set on thearbor. Use the spacers to positionthe cutter so that it will beapproximately centred across thematerial thickness, allowing finaladjustments to be made with therouters depth gauge or fine heightadjuster.Always fit the slotter close to theshank to limit flexing along thethreaded arbor and do check that thegrooving cutter is fitted the correctway round. Fit the bearing beneathor above the cutter, using the steppedwasher, and lock nut. Do not holdthe arbor in a vice or with pliers asthis will damage the shank or thread.With the plug removed from themains, secure the arbor in the routercollet by at least three quarters of itsshank length. Check that the cutterwill pass through the aperture in therouter base, otherwise it may benecessary to raise the base beforefitting the cutter. In this situation,take care not to release the depthlock, allowing the cutter to retract


and hit the base plate, even if thecutter is stationary.

Setting out rodTo minimise setting and marking out,cut a batten 100mm longer than thejoint faces and mark off its lengthalong the batten leaving an equaldistance at each end. Set out thecentre point of each biscuit recessalong the length, squaring themacross the joint faces for easyreference and making an identificationmark at one end of the batten. Usethe marking batten to set out therecess centres on each pair of jointfaces, always setting out from thesame end on each piece to ensureaccurate alignment on assembly.

Other fittingsFittings for specialised applicationsare also available, such as theSimplex knock down fittings usedfor de-mountable screens, andpanels. These consist of twoaluminium interlocking plates,that locate in the standard biscuitrecesses. Other fittings includebarbed plastic biscuits andtranslucent biscuits for joiningmaterials such as Corian®,Varicor® and Avonite®.Hinges are also available for fittingin biscuit recesses cut with adedicated biscuit jointer.

For furtherinformation contact:JKO LimitedHughenden AvenueHigh WycombeBucks HP13 5SQTel: 01494 521051-3Fax: 01494 461176

17

Edge to Edge BiscuitJointsSet out the centre line of each biscuit along the joint face and squarethem across to the edge of the woodfor easy alignment against the centremark on the router base. Work out

the amount of movement eitherside of the centre line that willbe needed for the cutter to

cut a suitable length recessfor the size of biscuit being used.Mark off the corresponding length onthe router base either side of thecentre line (stick a piece of maskingtape on the base plate for thispurpose). With the router base onthe face of the work adjust the cutterdepth to centre the grooving cutteracross the thickness of the material.To cut the recesses, position therouter level on the face of the workpiece with the cutter clear of theedge. Start the router and allow it to

reach full speed.

Feed the router into the material atthe beginning of the slot (aligning themarks on the tape against the centreline on the work) until the bearingtouches the edge. Follow throughagainst the direction of rotation ofthe cutter, to cut the required recesslength.Withdraw the router in the samecontinuous movement.

Move along to the next position andrepeat the operation.Repeat the whole procedure alongeach joint face checking that thecentre lines align on each pair ofmating faces.This process can also be carried outon either an overhead or invertedrouter table. Again lower or raise thecutter height to centre it across thejoint face. Mark the length of the cuton a temporary label stuck to thetable fence and align them with therecess centre lines on the edge of thework. For safety, use a hold-downguard to keep the work flat to thetable and to guard the cutter whenthe work is removed.

Corner Butt JointA 90° butt joint can be cut in asimilar manner to the edge to edgejoint, although the recesses will be cut

on the face of one of the boards. Thiscan be done using the same settingout and fence arrangements but withthe baseplate resting on the edge ofthe board.

T-Butt JointTo form T- Butt joints using biscuits, itis necessary to cut recesses across


the face of one board, the matingrecesses being cut on the edge orend of the second board as before.Face recesses can only be cut (whenusing the router) with a 4mmdiameter straight cutter (Trend ref.3/01 or C002). To guide the router,clamp a straight edge parallel to thejoint centre line, leaving a marginequal to the distance between theouter edge of the router baseplate tothe centre of the cutter. This willposition the recesses on the centreline. Measure off or use the settingout rod to mark the position of eachrecess. Set the router’s turret stopto allow the recesses to be cut totheir full depth (half the biscuit width)in three equal steps.

Mitred jointsMitred edges can be biscuit jointedusing the router, fitted with a 4 mmstraight cutter.

These will require asimple jig incorporating

a guide bush slottemplate, to allow the full

length of the biscuit recess to be cut.Alternatively a mitred batten can beclamped to the top edge of themitred workpiece with the routerbeing positioned over the joint faceby adjusting the side fence. IP

1.1.

2.

6.

7.

3.

4.

5.

18

Frame jointsFrame joints can bebiscuit jointed in asimilar fashion asedge to edgejoints, by clampinglevelling blockseither side of theframe member tobalance the router.Mitred frame jointscan be cut in a similarway, but with the levellingblocks cut at an angle to alignthrough with the mitre face.

Biscuit jointer setsTrend refs. 342x1/4”, 342x8mm or342x1/2”, are supplied completewith a 40x4mm kerf grooving cutter,mounting arbor, spacers, bearing stepwasher and three bearing guides toaccommodate each of the threestandard biscuit sizes.


Mitred biscuit joints can be cut usinga slot template and guide bush. Anangled batten is clamped to theworkpiece and the template isslotted to take the two fixing andadjusting screws.

Alternatively, an angled batten canbe clamped parallel to the mitrededge, allowing the router’s side fenceto be used.

19


Joining Kitchen Worktops £2.95 inc. VAT

An instructional video featuring theTrend Combi range of postformworktop jigs. It shows how they canbe used to produce flush precisionjoints, fitting worktop connectors andshaping the corners of peninsularkitchen units.

Advanced Routing £16.95

Although titled ‘Advanced Routing’,this book by Nick Engler, containsinformation of use to amateurwoodworkers, as well asprofessionals. Includes twofurniture projects as well as plans,instructions and details of how tomake a router workbench.

Router Magic £21.95

Bill Hylton offers a collection of‘tricks of the trade’ in the form ofportable and fixed jigs, tables andguides to maximise the versatilityof the router. He also devotes onechapter to vacuum clamping,showing how to make clampingplates and vacuum templates.

Woodworking with the Router £21.95

A comprehensive and informativeguide to routing, by Bill Hylton andFred Mallet, covering both basicand advanced routing. The bookincludes virtually all aspects ofrouting starting with technicalinformation on cutters, machines,etc, through to inlay and templatework.

Jig Making for the Router£14.90

Roy Sutton’s vast experience comestogether in this book. He givesadvice on tools, materials, safety andgeneral techniques. The making ofjigs for forming joints, panel raising,louvered doors,ellipse cuttingand edge planingis coveredmaking itinvaluable to allcraftsmen.

books & videos

sspp

ecia

l

offerFREETrend

informationpack for allSchools and

Colleges

Only part contents shown

Please apply on School orCollege official notepaperto:

Literature Department Trend Machinery Ltd

FREEPOSTPenfold Works Imperial Way

Watford WD2 4WD

Freephone0800 4 TREND(0800 487363)

Fax 01923 236879

new

Getting Started with your Router £9.99 inc.VAT

Roy Sutton guides the newcomersafely through the basics ofrouting and gives confidence touse the router effectively. It takesthe viewer through setting up andusing the components suppliedwith the machine.

20

Template ProfilersThree new template profilingcutters, with shank mountedbearing guides, have been addedto the range. The TCT two flutecutters are suitable for portable andtable routing. The ball bearing guideis slightly larger in diameter than thecutter to minimise scoring.46/96x1/4TC(12.7mm dia. x 32mm cut) £22.50

46/100x1/2TC(25mm dia. x 25mm cut) £36.50

46/101x1/2TC(25.4mm dia. x 45mm cut) £39.95

TCT Machine BitA 17mm TCT machine bit has beenadded to complete the Trend range.Sizes now range from 10mm to36mm in increments of 1mm.

1004/17TC £33.62

Hinge Sinking BitsTwo new machine bits are nowincluded in the range designed to drillthe hinge recess forconcealed cabinet hinges.With diameters of 20mmand 25mm each cutter ismounted on a 8mm shank.

T420/20x8mmTC £7.85T420/25x8mmTC £7.95

Staff BeadsIdeal for creating bullnose andhalf round mouldings on windowboards, panels and table-tops.These TCT cutters are forcutting bead radii of 6, 8 and10mm.

9/2x1/2TC (rad. 6mm)£42.959/3x1/2TC (rad. 8mm)£47.609/4x1/2TC (rad. 10mm)£49.25

Panel MouldThis 1/2” shank version of Trend’spopular TCT ogee panel mould cutterhas an increased shank length makingit ideal for creating panel mouldeffects on kitchen unit doors. It isparticularly suitable for routing awide mould in thin material.18/01x1/2TC(3.2mm rad. x 25mm dia.) £40.23

Heavy Duty OgeesThree TCT ogee cutters that aresuitable for use on heavy dutyrouterlathes. They are ideal forfluting spindles and other decorativeturned work as well as for ogeemoulding. The 22/7x1/2TC cutterwill also give an astragal mould effect.22/08x1/2TC(rad. 19mm x 41.5mm dia.) £69.75

22/7x1/2TC(rad. 22mm x 40mm dia.) £69.95

22/10x1/2TC(rad. 30mm x 50mm dia.) £72.50

Heavy Duty OvolosThree ovolo cutters ideal forfluting spindles and otherdecorative turned work. Theseovolos have a small flat groundon the nose that produces a

very fine cut, suitable for routingfalse panel mouldings and engravingwork.The 16/8X1/2TC cutter has adouble ovolo mould effect.16/5x1/2TC(rad. 18mm x 44mm dia.) £71.95

16/6x1/2 TC (rad. 25mm x 41.5mm dia.) £71.95

16/8x1/2 TC (rad. 6mm and 15mm) £74.95

Latest additions to theTrend cutter range

Straights - two & single fluteTwo flute TCT straights for a cleanfinish and better quality of cut.3/41x1/4TC(8mm dia. x 25mm cut) £17.50

3/41x1/2TC(8mm dia. x 25mm cut) £17.95

3/81x1/4TC(12.7mm dia. x 32mm cut) £19.95

4/03x1/2TC(14mm dia. x 50mm cut) £35.95

Single flute straight for fast cutting2/63x1/4TC(7.9mm dia. x 25mm cut) £18.252/63x1/2TC(7.9mm dia. x 25mm cut) £18.25

newcutters


All prices exclude VAT

Stepped RebateThis 1/2” diameter shank TCTstepped rebate cutter is ideal forrecessing shelving strip and otherfittings.36/2x1/2TC(14mm dia. x 8mm cut) £39.95

21


Only by providing a basicrouting bench, large enoughto work on, conveniently

and comfortably, can you start to getthe best from your routing equipmentand ensure that you can work safely,accurately and efficiently.The most obvious choice is to build arouting table, incorporating a range ofclamping and holding methods. Theideal bench is rigid, stable and largeenough to handle any size or shapeworkpiece (within reason) whilecarrying out a range of operations.Making such a bench will also offerthe opportunity to build in certainfeatures, avoiding the need forseparate or free standing routingtables and machines, combining themin one accessible and convenientrouting centre.

Hand-held OperationsA flat, stable and rigid surface isessential for any hand-held routingoperation. A purpose made benchcan be fitted with versatile and adaptable clamping systems, such asTrend toggle and ‘down-pivot’ clamps,as well as integral vacuum clampingfacilities. Permanent provision canalso be made for securing purposemade jigs and mounting boards foraccessories.

Inverted RoutingAn inverted routing table offers theeasiest and most convenientmethod of routing. With therouter securely mounted andthe workpiece resting on alevel surface, running against asquare and rigid fence, there is littleroom for inaccuracy. However manyproprietary tables tend to be on the small side, particularly whenhandling panel or sheet materials.With longer in-feed and out-feedsurfaces, during edge planning andmoulding with the back fence, orprofiling with bearing cutters ortemplate followers, the workpiece isbetter supported and easier tohandle. The Trend range of invertedtable routing accessories, includespressure guards, profiling guards, and a range of levers, knobs and threadedinserts to allow you to build andadapt your own table to suit yourrequirements.

Overhead RoutingOverhead routing offers advantagesfor specific operations such as pinrouting, face relief work or anyoperation where it is necessary tosee exactly what the cutter is doing,or where there will be inadequatematerial left to support the work onthe machined face. The Trend

Routerack system offers awide range of overhead mountingpossibilities including router mountingplates and clamps and vertical andhorizontal support pillars. These canbe used to mount the router in themost advantageous attitude for aspecific operation. A comprehensiverange of guide pins and bushes areavailable for copy and batchproduction work.

There are many ways of using the router, as a hand-held power tool, table mounted or fitted to a range ofrouting accessories, jigs and guides. However, theone thing that is common to all of these methods isthat you will need some form of stand or bench onwhich to work.

routingworkshop

by John Perkins

A furniture maker and designer, Johnis well known for his articles andbooks on all aspects of woodworking.

22


Routing accessoriesA stable work surface is also essentialwhen using routing accessories suchas the Trend Routerlathe andRoutergraph. A purpose made benchcan be fitted with integral clampingand mounting points to ensure quick,easy and secure setting up, wheneverthe machine is required.

Making a routing benchThe overall size of such a bench isobviously going to depend on howmuch workshop or garage space youhave available, although if space is verylimited it can also double as a generalworkbench. The overall size of ourrouting bench is 2140mm x 760mm.The height is 750mm but this can bealtered to a more comfortableworking height as required.The bench top is cut from 25mmMDF with a 110mm down-standscrewed to the front edge. Aremovable up-stand is fitted to therear edge, either loose doweled or

bolted to the top. Down-standpieces screwed to the underside ofthe worktop at either end, fit outsidethe end leg frames. A single coachbolt through each piece and the toprails of the two end leg frames, areused to secure the top.

The leg framesThe three legs frames are made upwith 70x70mm legs joined by 110 x26mm (Door lining) rails.Cut the six rails to a length of 570mmand mark out 55mm long tenons ateach end. Gauge a tenon width of22mm (or to suit the precisediameter of the available router

Housings are cut oneach assembled legframe to accept thefront and rear rails.Coach screws are usedto fasten the rails, withtheir heads recessedflush with the rail face.Use two screws foreach joint, staggeringtheir vertical centres.

Recessed holes aredrilled in theunderside of the benchtop to take thethreaded inserts.Although their tangsprevent them fromturning, it is advisableto run hot-melt gluearound the edge of therecess to prevent theinsert from beingforced downward wheninserting locking leversor holding down bolts.

23


cutter). Clamp the four railstogether, overhanging a flat surface.Set the router’s side fence to cut aninitial tenon width of 20mm (slightlyless than the cutter diameter). Cut arebate of this width across the endsof the four legs, cutting to the fullshoulder depth of 24mm in a series ofshallow steps of 3 to 4mm. Adjustthe side fence to increase the tenonwidth and repeat the procedure untilthe full 55mm wide by 24mm deepshoulder is removed. Turn the timberover and then end to end and repeatthis operation to cut the remainingtenon faces. Cut the six legs tolength and mark out the position ofthe mortises on each. Set the sidefence to centre the 22mm diametercutter over the mortise (Anytendency for the cutter to pull awayfrom the guide face can be eliminatedby fitting a second fence on extendedrods). A simple stop gauge, clampedto each leg in turn, will ensure that allmortises are positioned accuratelyand equal in length. Assemble thethree leg frames, gluing and doweling

each joint. Wipe off any excess gluebefore leaving to dry.Mark out and cut the housings at theends of each leg to take the long rails.Cut the four long rails to length andset out and drill the diagonally spacedholes to take the leg frame fixings (60x 8mm coach screws). The middle legframe is offset to allow an invertedrouter plate to be fitted in the centreof the bench top. Cut a notch in theleg frame cross rails to take thebottom front rail and screw the railto the frames using coach screwsfitted with washers. The top and rearrails are screwed, again using coachscrews and washers, to the face ofthe leg frames.Storage can be added by fitting abase, back and sides to the leg frames,using 10mm MDF. The back and sidesare screwed into the frame, the basebeing screwed to battens screwed tothe rails. Do not glue the panels tothe frame as they will need to beremoved if you decide to fit aninverted router plate or attach fittingsin the future.

Cutting RailTenons

Cutting LegMortises

Levers orbolts can bescrewed intothe threadedinserts to holdjigs and stops

A work piececan be held onthe benchusing variousclampingarrangements

The bench top can also be fitted with avacuum chuck for holding variousregular or irregular shaped workpieces.Connected to a small vacuum pump, avacuum chuck provides secure clampingwith fast alignment and quick release ofthe workpiece.

Vacuum Clamping

Technical SupportTechnical support lines are available forpractical advice on all aspects of routingand Trend products.

01923 224681Monday to Friday 9am - 5pm

John Tigg -Trend Technical Manager

24


Hand held routingFor hand-held routing operations,various methods of clamping arepossible. These include traditionalcramps, clamping onto the topoverhang and front down-stand.However, for many routingoperations, threaded inserts fitted ina regular pattern across the top offera flexible arrangement. These allowtoggle clamps and stops, fitted toclamping boards or chucks to be usedfor specific applications.Threaded inserts can also be used forsecuring accessories and jigs or forholding work directly to the bench.Although traditional bench vices canbe fitted to the front of the bench,they can cause an obstruction forsome routing operations. Temporaryvice mountings and alternativemethods of clamping long workpiecesvertically to the front of the benchare worth considering. IP

A tube clamp bolted to theunderside of the top, provides a

stable mounting for the TrendRouterack overhead system. Variousforms of back fence can then be cut

from thick board or laminated sheetto suit specific operations, retained

and adjusted by locking leversscrewed into threaded inserts.

Adjustable fence faces can be addedto suit.

For safety, it is advisable to fit an easilyaccessible no-volt release switch to the benchfor use in all routing operations. The Trend NVRS230v switch is suitable for use with all 230-240 volt routers upto 1850 watts. Fitted with a large headed emergency knock-off button, the switch will trip the instant the power supplyfails. The switch should be fitted where it is easily accessiblefor routing operations on the bench, as well as for invertedtable routing and similar operations where the machineswitch is not easily accessible.

THINKSAFETY

!

Trend Routerack pillar base clampscan also be fitted for mounting theTrend Routerack inverted table,allowing it to be quickly removedfrom the bench to be used for otherapplications. Mounting the table inthis way provides easy access forcutter changing and cutting depthadjustment.

A stable bench is essential formounting shop-made andproprietary jigs and ancillaryequipment. These can be simplyclamped to the bench top or down-stand, or bolted through threadedinserts set into the work surface.

Safety First

Trend No-VoltRelease SwitchRef. NVRS/230V

Trend PushstickRef. PUSHSTICK/1

25


Lecturer:Bob LambertExperience:Highly qualified and confidentinstructor of the router andexperienced jig maker and user.

CRAFT

SUPPLIES

ACADEMY

The Mill, Millers Lane, Dale, Nr Buxton,Derbyshire SK17 8SNTel: 01298 871636 Contact: Eve Middleton

Location: Close to Blackpool South railway station. Within walkingdistance of all amenities.Accommodation: Can be arranged by course organiserPlaces of Interest: Pleasure beach, Blackpool Tower, Lake District,

Blackpool Golden Mile Illuminations.Facilities: Free refreshments and choice oflunch. Large showroom.Course Content: Router safety, features,accessories, basic uses, edge moulding, carving,biscuit jointing, tenoning, Routerlathe turning. Allaspects dealing with router control and discipline.The project made on this course is a smalloccasional table.

Lecturer:Paul WenlockExperience:Wealth of Elu/DeWalt and Trend knowledge.Many years in the woodworking industryincluding demonstrating and lecturing onrouting techniques.

NORTHERN CRAFTS

BLACKPOOL

214 Waterloo Road,Blackpool,Lancs FY4 3AFTel: 01253 400066Contact: Alan Goodwin

on

Location: Courses held in the old mill at Millers Dale which forms part of thePeak National Park. Breathtaking views, unspoilt countryside and sympatheticallydesigned buildings.Accommodation: Full board accommodation available at the Routing Centre.Places of Interest: Chatsworth House, Haddon Hall, caverns of Castleton,Pavilion Gardens, Opera House at Buxton, Matlock Baths and Bakewell.Facilities: Crafts gallery, large showroom, refreshments, book and video library.Course Content: After an introduction on router features and safety, you

continue into your project for the course, a dressingtable top drawer and elliptical pivot hung mirror. Theseincorporate hand-held routing, tenoning, dovetailing,rebating and moulding techniques. Thecourse will also introducethe use of the dovetail jig,ellipse jig and table routing.

Two Day Courses

November 3-4

Further dates available

Course Prices

Two Day £150

Course Dates in 1997

Course PricesTwo Day £150with £25 voucher redeemable

against goods

Two Day CoursesOctober 20-21, 27-28

Further dates available


Free£25.00voucher

for all course studentsRedeemable towards the cost of any productssold by Northern Craft & Power Tool Co. Ltd

Prices include VAT

26

The following profile highlightsTrend’s national network of RoutingTraining Centres where studentswith little or no experience ofrouting can learn to appreciate itspossibilities and where the moreadvanced can keep upto date the latestinnovations in jigs,accessories andancillary routingequipment.

Location: Set in picturesque farmland close to the south-eastcoastal towns of Herne Bay and Whitstable.Accommodation: Guest houses and hotels in surroundingvillages and coastal towns.Places of Interest: Garden Centres, Faversham, SoutheastCoast.Facilities: Free refreshments, restaurant, craft shop, farm shop,showrooms.Course Content: Returned by popular demand, this renownedrouting course continues it’s traditional format of router use, safetyand jig making. Students can expect lectures, video/slideshows andhands-on routing. Information and demonstrations are available onmost Elu and Trend products.

Lecturer:Wayne CrickmoreExperience:15 years experience withElu and Black & Deckerproduct training and awealth of woodworkingproduct knowledge.

APPLECRAFT

CENTREin association with Roy Sutton

Selling Road, Macknade, Faversham, KentME13 8XF Tel: 01227 373297Contact: Roy Sutton/John Farrington

Location: Situated in the town centre ofthe Roman city of St Albans (Verulamium).Accommodation: Hotels and guesthouses within short walking distance.Places of Interest: Cathedral, historicbuildings, shopping precinct and parklands.Facilities: Course includes freerefreshments and lunch available from therefectory within the Oaklands campus.Course Content: The routing coursehas run successfully for 6 years and

provides a one day elementary coursedesigned for the beginner. This deals withan introduction to the router, its features,and safety aspects. The two day course,targeted at the professional and theambitious amateur, takes the art of Routinga stage further, giving a broader look attable routing and jigs. All students canexpect a full day of tutorials and hands-onexperience.

Lecturers:Ken Morton & Bruce MarshExperience:Careers in wood machining andfurniture making. Several yearslecturing on the subject of routing.

St Peters Road, St Albans AL1 3RXTel: 01727 847070Contact: Jeanne O’Reilly

coursea guide to routingcourses in the UK

One Day CoursesOctober 11November 1, 8 & 29

December 13

Course PricesOne Day £60

One Day CoursesJanuary 17 & 31February 14



One Day Courses

October 10

November 7 & 21

December 5

Two Day Courses

October 2-3, 16-17

November 13-14

Course Prices

One Day £67

Two Day £125

One Day Courses

January 23

February 6 & 20

March 6 & 27

April 24

May 8

June 5 & 19

Two Day Courses

January 29-30

February 26-27

March 19-20

April 30- May 1

June 11-12

July 2-3, 16-17



Free

video

OAKLANDS COLLEGE

SCHOOL OF CONSTRUCTION

Free video

Winter 1997 INProfilePrices include VAT

27

Location: Situated on the periphery of the city of Edinburgh.Accommodation: Hotels and guest houses in the local area.Accommodations officer on site.Places of Interest: Edinburgh Castle, Holyrood Palace, SalisburyCrags, Princes Street and the Royal Mile.Facilities: Leisure complex, sports facilities, refectories, vendingmachines, study centre.Course Content: Three, one day courses are available.The first deals with Router introduction, safety, control, and thegeneral use of the Router. The second deals with the router at amore advanced level and use of jigs and templates. The thirddemonstrates the use and advantages of jigs for trade and industry.

Lecturers:Stuart Telford & Gregor AllenExperience:20 years experience in thewoodworking industry andmore recently in buildingeducation to advanced levels.

EDINBURGH’S

TELFORD

COLLEGECrewe, Toll,Edinburgh EH4 2NZTel: 0131 332 2491 Ext 2229Contact: Stuart Telford/Derek Brown

One-to-one coursesavailable throughEaglescliffe Woodcraftson 01642 786449Lecturer: Ian Coning

Lecturer:Ian ConingExperience:Working life dedicated to the woodworkingindustry. Several years lecturing onthe subject of routing.

TEESSIDE

COLLEGE

Douglas Street, Middlesbrough TS24 2JWTel: 01642 300100Contact: Andy Batty/Julie Dodds

Location: Situated close to the port area of Middlesbrough.Accommodation: Hotels and guest houses within shortdistance.Places of Interest: Hartlepool historic quay, ancient fishingtown of Whitby, North Yorkshire moors and railway.Facilities: Vending machines, college canteen.Course Content: A combination of instruction and hands-on.including basic router use, router accessories, cutter identification,jigs and attachments, table routing.

Course PricesOne Day:Basic Router

£75Advanced Router £75

Trade Router £75

Course Dates To be arranged, please phone for details

One Day Courses

October 17

November 7

December 5

Two Day Courses

October 30-31

November 20-21

December 11-12

Course Prices

One Day £54.95

Two Day £109.95

One Day Courses

January 9 & 30

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January 15-16

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April 23-24

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SOUTH WESTYANDLESMatlock, SomersetFor details: 01935 822207

coming soon...confirmation of new routing courses:

NORTH WALESNEATH COLLEGEDwr-y-felin Road, Neath,WalesFor details : 01639 634271


One of the most skillful aspects of routing is in thedesigning and making of templates for repetitiveoperations such as hinge recessing or the batchproduction of individual components.

contemplatingtemplates

The basic purpose of atemplate is to guidethe path of the cutter

either by means of a fixed pin,guide bush or guide bearing.To do this the edge contourof the template must reflectthe exact contour of thecomponent and rest assured,any faults or irregularities willalso be faithfully reproduced!For all high quality work,templates must be cut fromfairly dense materials such asnon-shattering plastics, aluminium,medium density fibreboard (MDF) orTufnol. This is to ensure that theyremain stable with no risk of warpingor the grain rising. Template edgesmust be cut square and smooth,ideally using a router cutter guided bya straight edge, trammel or otherfixed guide edge. Alternatively thetemplate can be cut with a jigsaw orbandsaw, but the edges will need tobe finished square and smooth byfiling and sanding.

Workshop-wiseMost templates tend to be cut forspecific purposes, often integral withsome form of jig to position and holdthe work. However, there are manygeneral purpose templates that can becut and kept for everyday use in the workshop. One particular applicationthat frequently arises is the cutting ofcircles and circular recesses and is

one that lends itself ideally totemplate routing. However, to avoidthe need to cut a new template foreach occasion or set up a trammel todo the job, it is far more productiveto keep a range of circle templates atthe ready.Cut as individual templates, or as amultiple one, a range of circlediameters used in conjunction with afull range of guide bushes, allowsflexibility in achieving any requiredcircle diameter. Alternatively,templates of differentdiameters can bequickly cut

using the existing ones.Use a trammel to cut the initialtemplates, although having cut onehole, the guide bushes can be used tocut further sizes.Check that all the edges are squareand smooth and clearly mark on eachone its actual diameter. It is alsoworthwhile jotting down a table ofthe guide bush diameters to allowquick calculations to be made. Alwaysleave adequate room on the templatesurround for clamping withoutinterfering with the router. Alwaysfollow the correct feed direction, thatis against the rotation of the cutter.A multiple circle template is ideal for

making simple workshopaccessories such as tool racks.

Made from laminated facedMDF and clear 6mm

perspex, a templatewas used to cut

most of theslots and


Hand toolssuppliedcourtesy of:-

Mail Order SpecialistsJ SIMBLE & SONS76 Queens RoadWatfordHerts WD1 2LDTel: 01923 226052

29

30 INProfile Winter 1997

Neatly and accurately cut,comb joints are visuallyacceptable on utility

furniture, instrument boxes andcasework, but are not generally usedon decorative furniture and artifacts

due to their ‘mechanical’ appearance.However to achieve a moreaesthetically pleasing effect, theinterlocking grain pattern can befurther enhanced by cutting a beaddetail along the joint length. This canbe carried out using the invertedrouter fitted with a bearing guidedbeading cutter.The comb joint is initially cut using aComb jointer set (Trend Ref. 876) oron a comb jointing jig such as theElu/DeWalt multifunctional jig.Alternatively the joints can be cut ona saw bench or by hand.Prepare all the timber, finishing theedges square and true. Set up thecutter or jig and cut each mating end,alternating each pair to leave the topand bottom edges flush. Glue and

clamp the joints until dry, beforeplaning and finishing the joint facesflush.Select a beading cutter with a beaddiameter equal to the length of thecomb fingers. Set up the cutter in theinverted router table, and adjust thecutter height to cut the full jointwidth.When cutting small workpieces onthe inverted router table, fit a falseface across the back fence to preventthe work turning into the cutter atthe start and finish of the pass.A range of beading cutters (see theTrend 1997-98 catalogue, pages 30 to31) are available from Trend, suitablefor cutting both small or largediameter beads, machining from eitherface in turn.

holes to suit each individual tool. Therack was assembled using spacingtubes and 8mm threaded rod securedwith washers and dome nuts.

Arrange the tools carefully to makemaximum use of the shelf area,ensuring that there is adequate roomto remove and replace individualitems easily.A vernier gauge can be used to checkthe hole diameter or slot width andlength required for each tool beforeadding the guide bush margin.These holes can be cut out using flatbits, twist drills or hole saws, finishingthe edges square and smooth.To secure the template, drill twoholes in each edge to accept a pair ofpin clamps. When cutting thickmaterial, it is recommended that along reach cutter is used to ensurethat an adequate shank length can beheld in the collet.

Furniturefocus

by Tom Rogers

Tom’s experiencegained while runninghis own carpentrybusiness has provedinvaluable to theTrend Technicalteam.

inprofile 1

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