inprofile 2

The magazine for all Trend Users

2 ISS

UE

INProfile

BlackmagicIntroducing the new T5 router

RoutinginnovationsUsing the Pivot Frame Jig

A Cutabove the restChoosing the right sawblade

Jointwinner

The new DJ300Dovetail Jig

Latestnew products

AUTUMN 98

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

in this issue

4 Length WiseA simple method of producingchildren’s toys by the metre

6 New ProductsA selection of new Trendproducts launched this Autumn

8 Windows ForWoodworkersAn insight into the latestgeneration of affordable CNCmachines

10 RoutingInnovationsRouting techniques madepossible with the Pivot FrameJig

12 Past and PresentJim Phillips explains how therouter cutters have developedover the years

13 Furniture Focus 2Tom Rogers describes how toenhance an item of furnituresimply by using theRoutercarver

14 Dovetail JigTechniques for using the newDJ300 Dovetail Jig

16 T5 RouterA preview of the new T5variable speed router

18 A Cut Above The RestNeil McMillan offers generaladvice on selection, use andcare of sawblades

22 Comb JointingJeremy Broun reveals thesecrets behind Comb Jointing

26 Routing WorkshopAdditional features are shownfor the routing benchconstructed in issue one

29 On Site 2Miles Davey explains how to fit a mortise lock with adedicated jig and a router

30 On CourseA case study and national guide to sponsored routingcourses around the UK

Welcome to issue two of INProfile,the magazine for Trend users. Thisissue has timed nicely with thelaunch of many new products. Themost notable being the launch of thenew T5 router and the DJ300dovetail jig. They are certain tobecome popular items for theworkshop and I have thereforeprovided a number of articles onthese products.We thank all those that wrote in andagain offer the opportunity to allreaders to participate in thecontinuing success of INProfile bysending in their tips, comments andquestions.

John PerkinsEditor

Editor John PerkinsTechnical advisors Miles Davey Neil McMillan Jim Phillips Tom Rogers John TiggDesign/layout Tracy Highland Emma Hughes Neal Martinez Illustrators Annette Kelly Dave Scammel Contributors Jeremy Broun Jack CoxJohn Harrington Gordon WarrPhotography Front Cover - PhotoworksTPS Fotoart Matthew Shepherd

Trend Machinery & Cutting Tools Ltd FREEPOST Penfold Works Imperial WayWatford England WD2 4WDFreephone: 0800 487363 Fax: 01923 236879 Email: [email protected] WWW: http://www.trendm.co.uk

1998 Published by Trend Machinery and Cutting Tools Ltd. Allrights reserved. No part of this publication may be reproduced,stored or transmitted in any form without prior permission. Ourpolicy of continuous improvements means that specifications maychange without notice. Trend Machinery and Cutting Tools Ltdcannot be held liable for any material rendered unusable, or forany form of consequential loss.

3INProfile

length wiseWith formal training as awoodworking craftsman and lateras a professional teacher, Gordon iswell known to most woodworkingenthusiasts through the remarkablenumber of articles and books he hashad published.

Gordon Warr suggests asimple method of producingtoys by the metre!

vast range of intricately shapedcutters now available, the routingconcept requires only a littleimagination and innovation to turn atwo dimensional profile into a threedimensional object.Good examples of this method ofproduction on a small scale are mytoys by the ‘metre’. Toycars, lorries andtrees, as picturedhere can all besimply andquickly producedby this method, alongwith other similaroutline designssuch as buildings,boats and animals. Each is cut withone or a combination of basic cutterprofiles, machining along the length ofthe timber ready for crosscutting toseparate each individual item.A router table is essential for this

work, both for safety and accuracy.For cutting some of the profiles arouter of at least 900 watts will beneeded, while the larger radius cutterwill require a 1/2 inch shank capacity.You will probably find

that manyinterestingshapes canbe madeup usingyourexistingcutters.

Alternatively, refer to the new Trend1998/9 catalogue to trace out variousprofiles and make up your owncombinations before purchasing yourcutters. Remember that havingmachined the cutter profiles on the

by Gordon Warr

In the woodworking industry therouter has proved itself to be theideal tool for batch production

work. But, it is not only in theprofessional market that it can lend ahand in saving woodworkers bothtime and effort.For the home craftsperson or thesmall craft workshop, the routeroffers versatility second to no other

power tool. Combined with the

Autumn 1998

timber length, a little final shaping tosmooth in curves or remove sharpcorners can be quickly and easilyachieved using simple hand tools.Likewise cutter profiles can be joinedor married up smoothly in a similarfashion.One important point to bear in mindis that the timber should first beprepared by planing it straight andtrue and that excess waste timbershould be removed by cutting rebatesand grooves, leaving only the finalshaping to be carried out with theselected cutters.

When making cars and lorries, firstform rebates along the bottom edgesof the strip and cut a groove alongthe centre of the bottom face leavingtwo square beads to be machined tothe wheel profiles. Large areas ofwaste such as on the flat back lorry can be sawn on a table saw. The sawtable can also be used to cut angled surfaces for house roofs and otherwide flat surfaces. Not all the cutswill be able to be made by simplyrunning the square edges of thetimber against the router table orfence. It may be necessary to makeup support blocks or jigs to be ableto present the work to the cutter atdifferent angles or to keep it levelwhile machining.

Another alternative when forming the basic profile is to machine different shaped sections of timber and gluethem together in a long length. Thiscan produce attractive effects whenusing contrasting timbers and finishingwith clear lacquers or varnishes.

A circular saw or band saw fitted witha fine tooth blade is best forseparating the profile sections usingthe table fence to determine theirwidth. Alternatively use a fine toothhandsaw, taking care to cut the sidessquare and parallel.If you keep your cutters well honed(do it regularly on a diamond stone),you will only need to lightly sand themachined surfaces before applying afinish. In order to sand the sides,stick a piece of abrasive paper to aflat surface with double sided tapeand rub the faces over it, keepingthem flat to the surface.

Always use close grained woods suchas Beech. However, for a moredecorative effect use combinations oflight and dark woods, such as holly,maple, mahogany and cherry, but againavoid woolly or coarse grainedvarieties. For children’s toys, brightcoloured stains or varnishes can beapplied, but as with all paints andother finishes only use those that arenon-toxic and stated to be safe forchildren. IP

Professional DoorFittingThis video, one of a series

featuring Trend jigs and equipment

for the router, explains how the

Hinge Jig and other unique

accessories assist the carpenter to

fit doors with maximum ease and

efficiency.

Ref TV/5

Affordable CNC Routing This video demonstrates the range

of applications which can be carried

out using the CNC860 together

with complimentary products such

as software, jig-making accessories

and tooling.

Ref TV/6

The Trend RoutingSystemThis video looks at the two routers,

the T5 and T9, together with the

MINIMACH vacuum clamping system

and the DJ300 Dovetail Jig. It shows

how to use these and other products

to accomplish many woodworking

tasks.

Ref TV/7

newvideos

The Router - A Beginner’sGuideThe editor of The Router Magazine,

Alan Goodsell demonstrates the

techniques, the tools and the

accessories to unleash the full

potential of woodworking’s most

versatile tool.

Ref VIDEO/TRBG

5Autumn 1998 INProfile

newproducts

A selection of new productsnow available from your

local Trend stockist

MiniMachThe self-adjusting vacuum clampingbed, powered by any workshopvacuum extractor, that grips itself tothe workbench and holds yourworkpiece solid. Routing, sanding andhand planing are simple and clampfree. The MiniMach holds sheetmaterials up to 1220mm sq. down to95mm sq. and includes a hangingbracket for easy storage in yourworkshop.Clamp Guide Pro Track

These three new lines in the Clamp Guide rangefeature a wider aluminium extrusion, with thesame integral clamping mechanism but with threetracking attachments. They come in 2, 4 and 8foot lengths, the 8 foot being ideal for machininglarger panel material. The wide 5”aluminium has

T slots for attaching the baseplates and end stop. Thesystem therefore provides

an accurate and stablemeans of guiding

routers and saws.

Bench ClampBack to BackThese portable bench clamps provideobstruction free clamping to yourwork bench or trestle. They not onlyclamp to the bench but will alsosecurely hold the component forrouting and sanding operations.

Router Carver TemplatesThree new designs have been added tothe Trend range of Router Carvertemplates, including the Fleur De Lysand the Folklore which has beenincreased in range. A new Dolphindesigb can be carved left or right andis ideal for any bathroom or a child’sbedroom.

6 INProfile Autumn 1998

Hex Magnetic Screwdriver Bit SetThe SNAP/SB1/SET comprises a magnetic holderand 6 assorted screwdriver bits in a plasticcase/holder. These Pozi® bits feature a uniquetorsion zone to minimise the possibility of breakage.

Hex Plug CuttersFor cutting plugs in wood. Twosizes: 3/8” (9.5mm) and 1/2”(12.7mm) to suit the Snappy rangeof Hex Drill Countersinks(SNAP/PC/38 and SNAP/PC/12).

Hex CountersinkThe SNAP/CSK/1 is an 82°countersinking cutter for wood andman-made boards and is made fromtool steel.

Hex Taps - HSSFor use in torque controlledscrewdrivers on metals and plastics.Six sizes are offered M3.5, M4, M5,M6, M8 and M10 (SNAP/TAP/M35etc). A coolant is recommended.

Metric Drill Bit SetOur seven piece Hex DrillSet is now available in aMetric size, ranging from1mm to 7mm in diameter(SNAP/SET/2).

The Snappy range is the mosteffective way to increaseproductivity for drilling andfixing. Now, 19 new lines makethis an essential product for allDIY enthusiasts and tradesman.

Hex Step Reamer - HSSSpecially for use with Snappy Tapsfitted into torque controlledscrewdrivers. They are designed todrill the pilot hole required for aSnappy tap. Ideal for jig-making.Two sizes are offered (SNAP/SR/1 andSNAP/SR/2).

Hex Tapered Drills - HSSFor drilling and enlarging holes in allmetals, plastics (up to 2mm thick,man-made boards and wood up to6mm thick).Two sizes are offered,3mm to 7mm (SNAP/TD/1) and 3mmto 14mm (SNAP/TD/2).

19 Piece Drill SetThis Snappy boxed set with metrichex drills (SNAP/KIT/2) is ideal forthe home improvement enthusiastand professional. (Also available inImperial)

Tradesman SetsThese three sets incorporate oneof each of the four main lines andare designed for a specific screwsize. Each set comprises a QuickChuck, Drill/Countersink, No2Pozi® bit and Drill bit guide. Thesesets suit screw sizes No6, No8and No10. (SNAP/No6/SET, etc.)


windows for woodworkers

John Harrington reports on the latest generation of affordableCNC routing hardware and Microsoft Windows-based software.

The development of computernumeric controlled (CNC)routing, using affordable

personal computers has already begunto revolutionise all aspects of thewoodworking industry. In so doing ithas created new opportunities forlarge and small businesses as well asfor individual craftsmen.

CNC is a technique whereby themovement of a router head

is controlled byinstructions from a

computer. Theseinstructions come from a

computer program or list thatthe user keys into the CNC

860 console or into a computeras ISO standard commands called

'G' codes.As an example, the codeG01 X100 Y100, instructs the head

to move in a straight line to a pointhorizontally and vertically 100mmaway from its starting position.

The CNC 860The Trend CNC package is basedaround the Elu/DeWalt CNC 860Machining Centre, which has amachining area of 860mm x 860mm x

90mm. These dimensions relate tothe three axes, X,Y and Z (width,length and height). Each axis is servedby a separate stepper motor,controlling the movement of therouting head. Two head options areoffered: a modified portable router ora continuously rated, high cyclemotor, that provides improvedperformance for intensive machiningapplications.

Programming directly in G-codesthrough the console can be timeconsuming. To assist the operator, aPC software application calledCNCTalk is included with themachine. This is a basic computeraided design (CAD) application whichruns under DOS, the original PCoperating system before Windows. Itis useful for intermediate applicationslike cutting out irregular shapes.However, to gain the maximumversatility from the CNC 860,Trend’sOpen Sign System Software forWindows is the most effectivesolution.

OSS consists of two separatesoftware applications: OSS Draw

which provides the drawing tools tocreate any shape or sign, and OSSWork which handles all the routingand tooling-related parameters likedepth and offset. Graphicalsimulations are shown for all toolparameters enabling the user toperfect a design before routing anymaterial.

Sign-writingAs an example of how these productswork together, the method ofproducing a simple sign is shown,incorporating two different letteringstyles and a graphical logo.

8 INProfile


Having launched OSS Draw, the firststep is to draw a box or boarder onthe screen to indicate the overall areaof the work. This can be either asimple rectangular boarder or a moredecorative one.

This border then needs to have adepth assigned to it. This is done byusing colours to define the depth ofeach area.

The logo is then created using thedrawing tools within OSS Draw.

The words are keyed in using the textfunction. Again, colours are assignedto each area to produce a graphicalrepresentation of how the finishedsign will look.

The next task is to define the routingparameters. In the example, the red

and blue areas ofthe logo and thelettering have been assigned a depthof 5mm and the green area assigned adepth of zero. The same dialogue boxlets you specify whether a letter orobject is engraved or routed throughthe material.

The cutter profile that will be usedcan now be defined. With lettering,particularly serifed fonts, the cutterused needs to have a small diameter,perhaps 3mm. However, to achieve a5mm cutting depth this will have to berouted in several passes.

A simulation of the cutting path isnow drawn on screen. Having thencreated a G-code file of the sign readyfor the CNC 860 to cut, the file isdownloaded to the CNC 860.

The design can now be routed, thematerial being held on the bed by anadaptable clamping mechanism.

From the simulation, the path that thetool will take is known allowing adatum point to be set using the zerokey on the console, and the program

is run using the start key. This type ofrouting operation takes around 20minutes to complete and requires nofurther involvement by the machineoperator.

Other accessoriesSign-writing is just one of themany complex and wide rangingrouting operations that can becarried out using the OSS and

CNC 860 package. OSS also has arange of tools for drawing componentshapes and profiles directly or with anelectronic sketchpad (graphics tablet).

Vacuum ClampingTo reduce the through-put time forthis kind of operation, the CNC 860can also be used with a vacuum bed.Trend offer a complete range ofaffordable vacuum pumps and jig-making accessories to enable all CNCusers to produce a highly automatedproduction system to suit their ownspecific requirements. IP

Left: The finishedsign. The CNC860 can be usedto machinenatural timbersas well as manmade boards andplastics such asthis acrylic sheet.

Below: The high cyclemotor offers improvedperformance and lownoise for intensivemachiningapplications.

A new video isavailable - seepage 5

by Jack Cox

A retired electronics engineer,Jack has acquired an enviablereputation for both his medalwinning lathework and theintricate decorative work thathe produces on his innovativePivot Frame Jig.

Jack Cox explains a few of the uniquerouting techniques possible when usinghis Pivot Frame Jig.

routinginnovations

The Pivot Frame jig wasoriginally designed to cutcircular rebates for fitting

small mirrors into frames. However, ithas proved to be a highly versatilerouting jig, with uses way beyondthose originally envisaged. Thefollowing examples explain a few ofthe many applications devised so far -doubtless there will be many more inthe future.

Mini-pivot frame jigoperationsThe Pivot frame jig is used forcreating an artificial centre point,allowing the router to be rotatedaround a circular disc template ofMDF or plywood. The radius of thecircle and the cutting radius is altered

by changing the position ofthe router along its rods. Inthis way, the problem of the

pivot point disappearingbeneath the base of therouter is eliminated.

Beam trammelConversion to a standard beamtrammel mode permits the jig tomake its own circular disc templateby swinging it about the detachablepivot supplied with the jig.

The circular disc template can also bedrilled with a series of equally spacedholes on its outer rim. These areengaged by a small rod or indexing

pin, mounted in a ‘stop block’.Twenty four holes enable a full

circle to be accurately divided intocombinations of equal segments.Alternatively a smaller secondary

circular disc template can be used.This smaller disc is drilled to take acentral bolt, enabling it to slide alonga slot cut through the primary disc orworktop allowing the workpiece tobe offset from the pivot point or

primary disc centre. It can then berotated in steps, determined bythe indexing holes around therim of the secondary disc. Eitherof these two methods can be cut toboth internal and external scallopeddesigns.

August 1998

As the device is inherently accurate,using the jig as a mini-pivot, allowsholes and roundels of variousdiameters to be cut with the samecutters. It is also a simple matter tomake routed rings and fit them intomatching grooves, separately or in aninter-linked fashion.

For small work, the grooves aremachined from scraps of timber to fitinto the recesses accurately (somepreliminary experimentation will benecessary). For this, each piece mustbe mounted at the exact centre ofthe circular disc template leaving asmall wafer of timber at the base toretain them, the wafer being removedby sanding later. The rings are thenreplaced in the recesses to machinethe joints required for inter-linking, animportant point to note since thejoint faces need to be accuratelycurved.

By using longer guide rods (500mm)together with the circular disctemplate the mini-pivot is capable offorming radii up to 175mm.

Finally, it is possible to adapt the pivotframe jig to machine ellipses.Maximum dimensions are limited bythe size of the circular disc templatebut within this constraint any axisratio (ie. combination of major andminor axis) can be achieved. Detailson cutting ellipses and other pivotframe jig projects can be found in mybook Decorative Routing - Jigs andTechniques. IP

By using the jig as a ski system, planingoperations avoiding the dangers anddifficulties of working short, thin or twistedmaterial can be performed. In addition,‘flatting’ operations on fairly large pieces ofstock and any form of guided work againsta template are simple to execute. For edgemoulding operations, the jig can be set-upas one-legged ski or support system,ensuring that the router remains levelthroughout the operation.

The Pivot Frame Jig can also be used inconjunction with the Clamp Guide, tomaintain contact between the router andstraight edge throughout the routingoperation. With the guide clamped to aflat worktop or workpiece and the jig barsset either side of the guide, any deviationfrom the cut line is eliminated allowing thecutter to be fed into the wood in eitherdirection. This method can be easily usedfor machining parallel channels and edgesand for accurately machined halved/scribedjoints and precise mitres.

11INProfile

Twin bladed Cutter BlockA product used inthe 1930’s mainly inconjunction with beltdriven stationeryrouters at speeds from 6000 to 8000RPM. Blades were first cast, thenproduced in HSS and finally in solidtungsten and known as Widia andWimet steel. The original steel bladeswere ground by hand to the requiredprofile but the range of styles werevery limited.

In the first issue of INProfile, Jim Phillipsexplained the origin of today’s routers,but what of the cutters and how did thecurrent range originate.

past & present

12 INProfile

by Jim Phillips

A ‘tooth’,forerunner oftodays routercutter.

In the beginning!The router cutter of today has astrange origin as it evolved from aprimitive tool called a “tooth”. Itderived its name from the limitationof dentistry at the time when a singleprojecting tooth was a common sight.The tooth took the form of a groundtapered steel chisel, wedged into awooden stock and was used forcutting square and radiused grooves.Skilled hands produced clean cutgrooves by a series of gougingmovements. A metal version wasmade by Stanley some years later,with built-in adjustments and somecraftsman use versions of this up toquite recently. A picture of an earlymetal version is shown below.

1870’sIn the 1870’s however, someonethought that by making the bladerotate simultaneously with theforward motion, something usefulwould happen. What anunderstatement!Even before the electric motorentered the equation, cutters werebeing rotated by the means of a footpedal. The Barnes Former forinstance, ran at 2500 rpm, with theoperator having to exert himself toachieve a reasonable degree of cuttingability. This type of routing machine,first produced in the USA in 1872,was reported still to have been in usein the 1930’s. This was the forerunner of the spindle moulder andlater the router of the post warperiod. But cutting geometry was init’s infancy and cutting edges bluntedquickly, especially when used onabrasive timbers.

1920’s and onwardsIn the UK, it was William Day ofNorth London Saw Works whoproduced the first high quality toolingin 1926. But in 1938 a carbide tipbrazed onto a HSS cutter wasreleased with astounding results, theTCT cutter had arrived.

Single Blade Cutter BlockSingle bladed blockswere used from thelate 1920’s right up tothe 1950’s, especially by patternmakers. These were produced innumerous styles and the advent ofcutters with bottom cut geometrywas traced to this early design. Thesetools could be run at greater speeds,smallest diameters at 18,000 RPMand largest at 12,000 RPM.

1990’s and beyondInnovative tooling continues to bedeveloped. Examples of this includesolid carbide spiral cutters, ROTATIPreplaceable tip cutters and PCDtipped tooling. For improved safety,integral chip limiters are now designedinto cutters with diameters over16mm, and restrict the level of injuryshould a cutter be contacted. IP

13INProfile

by Tom Rogers

22furniturefocus

One useful routing accessorythat lends itself to this isthe Trend Routercarver.

Intended for cutting decorativecarved motives into panel faces, framecorners or as intricate surrounds fordoor handles and other furniturefittings, the system uses a number ofinterchangeable templates, held by asingle frame, to produce many varieddesigns.

Although each Routercarver set usestwo or more templates to produce aspecific design, for a simplified effect,fewer cuts can be selected from eachstandard template to achieve a uniquecarved style of your own.

In my example I have taken a sectionfrom the Classical template Ref.RCT/HS/C, to produce a carvedfrieze along the bottom of anottoman. The carving on the top ofthe box is Ref. RCT/LP/C.

To locate the holding frame andtemplates in position, it has beennecessary to temporarily remove thefeet and the bottom plinth moulding.A clamping batten is fitted in place ofthe plinth moulding. Carefullyselect the section of carving onthe template and calculate thespacing between each carvedsection on each face of theworkpiece. Remember toalways cut a trial sample first toavoid risking the workpiece.

The Trend Clamp Guide straightedge can be used to positionthe template frame square tothe edge of the workpiece orpanel in each cutting position.In this example, I also used it toset a margin and guide the router tocut a decorative line around theottoman. For this I fitted a radiuscutter, although a v-cut or shallowsquare recess (straight cutter) can beused for these border lines.

Various finishes can be applied to thework, either to match the existingfinish, or having stripped and sandedthe surface, a new finish to matchother furniture or interior style. Thesurface can be stained and varnishedor have a paint or paint effect(ragged, sponged etc.) applied.Alternatively an attractive effect canbe achieved by highlighting the carvingusing a contrasting colour. IP

Tom Rogers describes a simpleway to enhance the appearanceof a piece of furniture.

Chip limiter1.1mm


DJ300dovetail jig

The DJ300 Dovetail Jig is aversatile accessory which enablesany router user to createtraditional dovetail and otherjoints with a router.

new

Dovetail joints are recognisedas one of the strongest andmost attractive ways to join

timber, but cutting a dovetail by handis difficult and time consuming. Thecombination of the DJ300 Dovetail jigand a router such as the Trend T5enables dovetail joints to be producedeasily with perfect accuracy, in afraction of the time.

The jig features a precisionengineered design to ensure that the‘tails’ and ‘pins’ are cut with identicalpitch angles and spacing. It containseverything needed to start makingdovetail joints with your router. Thebase assembly has workbench fixingsand strong clamps for the workpieces.The adjustable metal end-stopsensure a symmetrical joint is achievedevery time with any of the templates.The 300 mm wide dovetail templatesupplied with the jig is precision-machined from solid aluminium, as

opposed to plastic or stamped steeltemplates used with other jigs. Alsoincluded is a TCT dovetail cutter, aguide bush and fixings.

The jig is supplied with a comprehensivemanual and a voucher for a free TrendRouting System video, giving a usefulintroduction to using the DJ300, aswell as T series routers and theMINIMACH. Spare parts for the jigare readily available if they are everneeded.

It takes just a few minutes to set-upthe jig and the router to begin makingyour first dovetail joint. If you’venever used a dovetail jig before itsimportant to familiarise yourself withthe way the timber is aligned in the jigand also the depth of cut to achieve afirm joint. All this is explained fully inthe manual. As with any new tool, tobecome familiar with its characteristics,the best idea is always to make trial

joints first in some scrap material.

Two optional aluminium templates are also available. The 1/4” lappeddovetail template produces small half-blind dovetails, ideal for jewelleryboxes, artists cases and other smallerprojects. This template is used with a7.74mm guide bush supplied with thetemplate, and a 6mm solid carbidedovetail cutter supplied separately.The end-stops needed for thedifferent joint off-set are suppliedwith the jig.

The other optional template is for a1/2” comb joint. It uses the standardguide bush supplied with the jig and a12.55 diameter straight cutteravailable separately. These joints havea square profile instead of the taperedshape of the dovetail. This simple

jointwinner


The dovetail profileis formed using theTCT cuttersupplied with thejig. The guide bushfitted to the router,follows the fingersof the template.

Once the router isset up correctly, itwill cut both pinsand tails in onepass.

The position of thetemplate is adjustedusing the spannersupplied to set thedepth of thedovetail joint.

Additional templates andcutters are available

Standard Dovetail cutter

shape is strong and attractive forprojects such as boxes, cupboardcarcasses and larger furniture items.See pages 24 and 25 for a detailedlook at comb jointing.

The DJ300 offers a winningcombination of accuracy, simplicity andversatility to increase your creativepotential for many projects. IP

The timber ispositioned tight upagainst the edgeguide to fix thejoint off-set. Theside of this drawassembly is placedin the front clampand the front of thedrawer is placed inthe top clamp.

new


Our new router, the T5, is a powerfulcompact machine, perfect for lightand medium duty applications.Could it become the UK’smost popular router?

routerThe new Trend T5 router has

been designed to be the idealmachine to get started with

the craft of routing and to offerversatility and performance for theexperienced user. It has a classicergonomic design, combined with an850 watt variable speed motor. It iseasy to use portably and has powerto machine dense hardwoods andman-made materials. The electronicspeed control gives a ‘soft start’ whicheliminates an initial ‘kick-back’ typicalof older designs.

The T5 has a spindle lock and hexcollet nut to make changing cutterssimple and safe. A depth gauge andthree-position turret stop allowaccurate cutting depths to be set orchanged quickly and the 50 mmplunge depth is set using the right gripknob.

In the boxThe T5 includes all the essentialaccessories such as a beam trammel,

20mm guide bush, side fence withmicro-adjustment, a dust spout, andboth 1/4” and 8 mm diameter collets.The 1/4” collet gives compatibilitywith hundreds of cutters, while the 8mm collet enables larger cutterssuch as the Router Carver cutter orpanelling cutters to be used. Optionalaccessories include a fine heightadjuster and a metal storage case.

SimplicityThe T5 is supplied with valuablesources of information for new users,experienced craftsmen and buildingtrade professionals. A comprehensiveinstruction manual explains theessentials of how to set-up and usethe machine. In addition, a set of ourfour colour booklets covers allaspects of routing including usingpopular cutters, home improvementprojects and advanced techniquessuch as making panel doors. Simplyby returning the warranty card, a freecopy of our latest video ‘The TrendRouting System’ will be supplied.

Thisvideo explains and demonstrates theT5 router as well as other newproducts including the DJ300 DovetailJig, the MINIMACH and theforthcoming T9 router. The literatureand video can also be orderedseparately.

The instruction manual contains a fulllisting of all the T5 spares which arereadily available, and the machine issupported by a network of serviceagents throughout the UK.

CompatibilityOn its own, the T5 will perform manyrouting operations. However,combined with our jigs andaccessories it forms the keycomponent of a workshop system tomake routing more creative andproductive. Jigs such as the

blackmagic!

the

Standard Accessories

OptionalAccessories

Fine Height Adjuster FHA/001

Metal Storage CaseDivisions and space for cutters and accessories.CASE/T5

Craftsman Router Table, DJ300Dovetail Jig, Routerlathe, Pivot FrameJig and the Routercarver can all beused with the T5 to accomplish manywoodworking tasks, without the needfor complex hand skills.

For the building professional the T5 will also be available soon in a 115volt version making it ideal for use on site, especially with products such asthe Hinge Jig and Routabout.

The T5 is the first of the Trend Tseries routers. With

features and accessories for almostevery routing application, it seemsdestined to become the preferredportable router for craftsmen andprofessional users. IP


Plunge stroke ___________0-50mmPower input___________850 wattsStandard collet dia.____1/4” & 8mmNo load speeds __9,000-27,000 rpmWeight _____________2.7kg (6lbs)Voltage range _____115 & 240 volts

Specifications

Edge moulding usingthe side fence as aguide.

Cutting circles usingthe beam trammelattachment.

Dust extraction spoutfor connection to adust extractor.

Template routingwith the routerfitted with the guidebush supplied.

The new T5 routermounted on a TrendRouterlathe.

Sawing termsRip sawing Cutting along thedirection of the wood fibres, withthe grain.

Crosscutting Cutting across orat an angle to the wood fibres,across the grain.

Kerf This is the saw cut andtherefore equal to the width of theteeth or the overall width of theset of the teeth. Although thinnerblades tend to cut faster, they mayalso bend under excessive sideloads, creating a wider or deviatingkerf.

by Neil McMillan

Neil is a qualified woodmachinist, who haswritten many articleson routing.

Using the latest design andproduction technology,circular sawblades are now

available in a wide range of toothconfigurations for cutting all naturaltimbers and wood based products, aswell as non ferrous metals, plasticsand other materials. Each toothconfiguration offers different cuttingcharacteristics to suit variousperformance requirements, such asfast or slow feed rates, in fine andcoarse materials.

It is not only the teeth of a circularsawblade that play a role in itsperformance, but the saw plate itselfneeds to be designed and producedto specific criteria to avoid distortiondue to flexing and friction whencutting. The combination of both thetooth and plate design must also takeinto account other factors such aswaste material dispersion, heatexpansion and noise reduction. Onlyby taking all these factors and othercriteria into account at the designstage, can a circular sawblade beexpected to produce an accurate

precise cut and an acceptablestandard of finish on the cut surfaces.

The Trend WAVEFORM® range ofTungsten Carbide Tipped sawblades isaimed at the professional user andhas been designed for highperformance and reliability, whileremaining cost effective. Thesawblades are available to fit virtuallyall current ranges of portable,crosscut, radial arm, bench mitre,table and bench saws. Diameters ofblades range from 150mm up to400mm, with tooth forms and teethnumbers to suit most applicationsrequired by woodworkers, builders,carpenters, machinists and othercraftsmen.

Trends product development manager, Neil McMillan, offersadvice on what to look for when buying circular sawblades.

a cutabove the rest

8°-12°

1°-2°

a

b

Tooth pitch (e) -Dimension between two teeth anddenotes number of teeth. Smallerthe pitch, greater the number ofteeth.

Top clearance angle (d) -Ground according to hardness ofmaterial to be cut.

Hook or rake angle (c) -Angle of tilt of the tip.- Positive (forward) for ripping.- Negative (backward) for cross cutting.- Zero for plastics and aluminium.

Top bevel clearance (a) -Determines how cleanly the bladecuts and enables gradual penetrationinto material.

Radial side angle (b) -Ensures clearance between teeth andkerf side.

-6° to +22°

12° to 15°

c

d

e

18 INProfile

The Saw plateThe saw plate is first precision cut asa flat steel disc from high qualityhardened chrome alloy steel of aconsistent thickness.

The tooth profile is then machineground or laser cut around itscircumference.

The bores are accurately reamed toensure precise concentricity andbalance.

Microgranular TCT (TungstenCarbide Tips) are copper brazedinto a seating ground in the plate

tooth profile.The carbide tips are diamondground to precise tooth forms.

Top quality blades are thenhardened, tempered and rollertensioned to ensure that the plate isflat and rigid. Cheaper sawbladesare prone to distortion or imbalancein the plate which will causevibration in use, resulting in a poorsurface finish and inaccurate cutting.

T.C.T.Being an extremely hard material,Tungsten Carbide produces a tooththat has far greater wear resistance

than the plate steel, but can still beground to a sharp cutting edge. Thisgreater wear resistance allows TCTblades to be used to cut abrasivematerials such as resin based particleboard (chipboard etc.), melamineand plastic laminate faced materialsand aluminium. TCT blades are alsosuitable for use on all naturaltimbers, both hard and softwoodsand less-abrasive sheet materials.


Tooth FormThe quality of cut or surface finishdepends mainly on the tooth formand number of teeth around theblade circumference. Generally, thegreater the number of teeth, thebetter the finish.

Variations in the tooth form aredesigned to suit different materials,specific operations or to produce thebest compromise between cuttingspeed and quality of the surfacefinish.

Triple chip (TCP) teeth or (AlternateTrapezoidal) have every other toothground flat with the corners ofintermediate teeth ground at 45 degrees.These intermediate teeth are also left afraction higher than the flat tooth. Thistooth form is ideal for cutting plastics andnon-ferrous metals such as aluminium.

Fitting sawblades:Check that the spindle flanges orcollars are in good condition andclean. Ensure that the blade is thecorrect type for the job and materialand ensure it is the correct size forthe machine. Check the direction ofrotation of both blade and spindlebefore fitting. Ensure that the flangesare fitted correctly before tighteningthe lock nut or bolt, taking care not tocross thread it. If bushing washersare to be used to adjust the borediameter, check that the flangediameter is greater than thesawblade bore diameter inorder that the flanges clamp

on the saw plate and notthe bushing washer.

Tungsten carbidetips - wear resistanthard metal cutting edge

Expansion slot -allow for expansion dueto frictional heat build up

Cooling slots -found on ripping bladesprevent excessive heatbuild up

Anti-kick back -found on ripping sawblades.The design reduces theamount of bite per toothand possible kickback

Flat top form teeth are intended for cutting along the grain of thewood. The cutting edges of the teeth,being square to the blade axis,obviates any tendency to be deflectedfrom the line of cut by the grain.

Alternate top bevel (ATB) teeth have the cutting edges on alternate teeth,bevelled at opposing angles. This toothform produces a slicing cutting actionacross the wood fibres (grain), leaving acleaner cut reducing break-out (spelch)and chipping along the cut edges.

Back support -supports the cutting edge

Steel plate - themain body of the sawblade

Gullet - collectsand ejects wood chips

�

�

�

Bore - precisionreamed to suit sawspindle


UNIVERSAL RIP - RP GROUP

For ripping applications on saw benches for cutting along the grain. Chip limiterdesign for anti-kick back and cooling slots for continuous use. A ripping blade willallow a fast feed rate but will give a coarse finish.

15°

18°

1.0mm

15°

15°

10° 10°

GENERAL PURPOSE - GP GROUP

For general purpose applications and where price is an importantfactor. These blades will give a medium - coarse finish when ripping.

15°

10°

10° 10°

COMBINATION - CM GROUP

For combination applications where cutting along and across the grain isnecessary, and where price is also an important factor. These blades willgive a medium finish.

15°

10°

10° 10°

TRIMMING/CROSSCUT - TR GROUP

For trimming or crosscutting applications. These blades will givea medium - fine finish and are particularly suitable formanmade boards.

15°

10°

10° 10°

FINE TRIM/FINISHING - FT GROUP

For finishing or fine trimming applications. An extra fine finish is obtainedby these blades making them particularly suitable for finishing work. Thehigher number of teeth results in a slower feed rate.

Flat toptooth form

Alternatetop beveltooth form




KEY for sawand wood

compatibility Soft wood rip Hard wood &exotic rip

Plywood rip Plasterboard &stone fibre board

Soft woodcrosscut

Hard wood & exoticcrosscut

Plywood crosscut

Sawblade types & Applications


Caring for your sawblades:Sawblades must be handled with great care to keep them ina good condition and to protect the user. To avoid accidentsor damage, they should be left in their packaging prior tofitting to the saw. The sawblades should be carried by ahandle or hook fitted through the bore.After removal from the machine, blades should be stored intheir original packaging or other protective case or rack.

Cleaning and maintenanceAfter prolonged use the cutting edges will become dull, thisis evident by slowing down of the cut, a poor quality finishand excessive heat build up. Prior to honing (sharpening)the saw blade should be cleaned with a resin solvent such asRESIN CLEANER® to remove residue. A DMT diamond flatfile - fine grade can then be used to lightly hone the face ofthe tips removing only a minimal equal amount from eachtooth. For heavier re-sharpening or fine chip removal,TCTsawblades should sent for professional re-grinding. A drylubricant spray TRENDICOTE® can then be sprayed onto theblade before use to minimise future resin build-up.

Resin Cleaner® - RESIN/100

This newly developed spray-on liquid has resindissolving properties that quickly andharmlessly remove caked on resin. The liquidalso includes a rust inhibiting agent. Sold ina handy 100ml pump-action dispenser.

15°

10°

45° 45°

0.4

PANEL TRIMMING - PT GROUP

For fine super trimming of panels. The high number of teeth and tooth grindingon these blades give a super fine finish in panel materials, especially laminated ontwo sides. A slow feed speed is required with these blades.

15°

-6°

45° 45°

Ø D

0.3

ALUMINIUM/PLASTIC - AP GROUP

The particular grinding on these blades ensure they will give a fine finish inthin walled extrusions of non-ferrous metals or plastics. They have anegative hook angle.

15°10° 10°

0°hook5° hook*

RADIAL ARM/MITRE SAW CROSSCUTTING - CC GROUP

The blades in this group have various pitches giving coarse, medium or a finefinish. They are ideal for crosscutting applications in a variety of materials.These blades have zero or negative hook angle to minimise “pick-up” and“snatching”.

PTFE Dry Lubricant Spray -TRENDICOTE

Diamond FlatFile - FFF

TRENDIWAX® coolant recommended for alloy cutting

Triple chiptooth form



Soft fibre board Hardboard Plastic laminatedouble sided

MDF Plastic laminateon one side

Phenolic &hardplastic

Alloy Plastic

Secrets revealed! Comb and FingerJointing techniques can be mastered.Jeremy Broun tells you how.

by Jeremy Broun

Jeremy is a renowned furnituredesigner and router instructor.

He is the author of several booksand has produced three videos.

When constructing a box, the foursides (A&B) can be cut at the

same time. One piece (B)is then turned edge toedge in order to leave

flush top andbottom edgeswhen the boxis assembled.

Alternativedecorative use of thecomb joint profile,separating themembers byinserting loosetongues.

combjointing

The comb joint, sometimes referredto as a finger joint, offers a similarextended glue line and by using asuperior modern glue achievesvirtually the same strength as adovetail and can look just asattractive. It is possible to use thejoint with good effect in a variety ofcontrasting timbers and there isscope to use the joint and its jigs andcutters imaginatively.

Using the Trend CombJoint SetThis cutter set enables comb joints intimber up to 40mm wide (doublethat if you turn the wood over) to becut. A heavy duty router mounted inan inverted router table such as the

A B

AB

Basic finger or comb joint


As well as being simple to cut,the comb joint is a strongand attractive alternative to

the dovetail joint for the making upof both small and large carcasses. Itis also ideal for other applicationssuch as drawer and box constructionwhere the finger or comb pattern canbe used as a decorative feature.

The comb joint is a natural fortrinket boxes, musical instrumentcases and small tool cabinets using atable mounted router fitted with theTrend comb jointing cutter set.Alternatively, joints for larger work,for example, blanket boxes and chestscan be cut using the Trend DJ300Dovetail jig fitted with theappropriate finger template.

Comb joints can also be cut by usinga simple home-made jig and an 8mmtwo flute straight cutter ref. 3/4 fromthe Trend range.Gone are the days when the dovetailwas considered as the only reliablejoint.

Trend Craftsman table or Routerackis required. A simple jig is used tohold the workpieces square to thefence while cutting the joint profile.This runs either in the existing slidingbevel fence groove or against theedge of the table, keeping it square tothe fence. This jig can be made usingMDF and softwood, glued and pinnedtogether.

Preparing the timberThe workpieces (i.e. the uncut sidesand ends) must be accurately planedto size, finishing it flat with parallel sides and faces. The timber thicknessfor this cutter is between 3mm and9.5mm, matched to the appropriatediameter guide bearing. Maximummaterial width is 40mm.It is important that the ends are truesquare either straight off a dimensionsaw or a disc sander. Avoid usingbowed wood as joint inaccuracy and

fibre break out is more likely to occur when clamping severalmembers of a box together in the jigfor cutting at the same time.

Assembling the cutterIt is easier to set up the cutterassembly with the router mounted inthe table. It is helpful to follow theinstructions supplied with the cutterset. First the arbor shank is insertedinto the 1/2” collet and tightened in

the

normal

way. The bearing is fitted on thearbor followed by a shim. The cuttersare then fitted with a spacer betweeneach. Always stagger the teeth ofeach cutter to balance and lighten the impact load whencutting. A nut and washer secure theassembly on the arbor, using therouters spindle lock to grip the cuttershank while tightening the nut.

Cutting the comb jointPrepare the wood to size, checkingthat the pieces of each pair of sidesor ends are equal in length and theends are square. Remember toprepare extra material for makingseveral trial pieces. To reducebreakout, prepare a backing piece tolie against the face of the sliding jig.

Fit the cutter set into the routercollet ensuring that at least threequarters of it’s length is held in the

collet. Adjust the height of thecutter above the table,preferably with a fine heightadjuster. Set the cutter off

against a piece of thework and align thebottom of the cutter

with the bottom edgeof the workpiece.Using a steel rule,

align the guidebearing face withthe fence faces.

Mount the two trial pieceson the jig with the backing pieceagainst the jig face (clamping themthere with a small clamp). Make surethat the locking bar of the clamp willbe clear of the cutter path.Check that all adjustments and the

two trial pieces are secured before switching on the router and allowingit to reach full speed.

Grip the jig firmly, keeping fingersaway from the cutter and make a passacross the cutter face keeping thetrial piece tight to the fence face.Switch off the router after the workhas cleared the cutter.Check the fit of thetwo pieces, turningone edge over to leavethe top and bottomedges flush wheninterlocked.

Clamp the sides andends of the boxaligning one end ofeach against the fenceface. Cut end profilein one pass beforeturning the pieces around, aligning theopposite ends against the fence, andcutting those. Remember to fit thebacking piece each time and replace itif it becomes ragged.

Dry assemble the jointed box (frameor carcass) to check the joints beforecutting the grooves to take the topand bottom. Remember thegrooves will appear on bothsides or the front and back,unless stopped grooves arecut on the appropriate pieces.These grooves can be cut bysetting up the comb joint cutterset with only one of the wingedcutters. IP

The comb joint profilecan also be used toproduce interesting anddecorative affects for usein furniture and otherwoodworking projects.

Attention should be given to trackingthe jig tightly in the groove andensuring that it is square in bothdimensions. A small clamp is used tosecure the workpieces before cuttingwith a smooth, firm continuousaction.


The Comb Joint cutter setcomprises five three winged 4mmkerf TCT grooving cutters whichare mounted with spacers on anarbor. The spacing between each isprecisely the same as the kerf. Thecutter assembly is self guiding, oneof three interchangeable bearingssupplied with the set has been fittedon the arbor to suit the thickness ofthe timber.

The Trend DJ300 Dovetail Jighas alternative templateoptions for cutting both

dovetails and comb joints. Fitted withthe comb joint template, guide bushand 12.55mm straight two flute cutter(Ref 3/76x1/4TC), 12.7mm (1/2 inch)comb joints can be cut in either hardor softwood from 12mm to 20mmthick and up to 300mm wide. The jigis easy to set up and with a littlepractice, will cut precise and accuratecomb joints for boxmaking, cabinetcarcassing and furniture.

Timber preparationBefore setting up the jig, each side ofthe box or carcass must be cutaccurately to exact widths in order toproduce equal thickness finger andspacing across the width of theworkpiece. Each piece must also betrimmed to the exact length required,i.e. equal to the overall length of thebox sides. Unlike lapped dovetailswhere two sides are cut short toallow for the lap, with comb joints theend of the comb fingers appears oneach face of adjacent sides.

Check that the ends are trimmedsquare in both directions. Carefullymark each side of the box (carcass)to denote the face sides and each pairof mating ends to ensure that eachpiece is cut for assembly in thecorrect sequence. Remember thatthe widths of the prepared timber

will be multiples of the pitch of thetemplate fingers.

Backing piece To avoid cutting into the base of thejig, always use a waste backing pieceat least 6mm thicker than theworkpiece. As each piece of thejoint is cut separately, this is fittedinto the jig in place of the horizontalworkpiece when cutting dovetails.The backing piece should be of similarwidth to that of each workpiece (boxor carcass side) and be fitted with theforward end flush with the front ofthe metal jig base. This preventsbreak out on the back of theworkpiece as the joint is cut.

Positioning theworkpieceOn the front face of the firstworkpiece or a trial piece of the samedimensions, draw a centre line alongone face. Mark a 2mm offset to the

left and the right of it.

Fit the two edge offset guides butleave them slightly loose. Fit thecomb finger template to the jig sothat it sits flat and level on thebacking piece.

Clamp the marked workpiece to thefront of the jig with the top end flushand tight against the underside of thetemplate. Ensure that the templatefingers protrude in front of theworkpiece and adjust the forwardadjustment nuts (fitted to the frontclamping bar threaded studs) so thatthe front of the template is parallel tothe face of the vertical workpiece.

For the left hand edge guide, align the2mm offset line against the left handedge of one of the template fingers.Tighten the front clamp making surethat the timber does not move. Usea second workpiece to draw a lineacross the top of the first workpieceto denote the thickness of the matingpiece (i.e. the full depth of cut),holding the second workpiece flat andflush beneath the finger template.

2mm

offset

lin

e

2mm

offset

lin

e


comb jointingwith the DJ300

dovetail jig


Remove the template and slide theleft hand edge offset guide against theedge of the timber and tighten thescrews. Repeat the setting upoperation for the right-hand side edgeguide using the right-hand offset line.The offset guides allow eachsuccessive workpiece to be quicklypositioned without the need to markthe centre and offset line on them.

Setting the depth of cutWith the router disconnected fromthe power source, fit the guide bushand cutter. Stand the router on thetemplate with the guide bush spigotbetween two template fingers. Ideallyusing a fine height adjuster fitted tothe router, set the bottom of thecutter fractionally above thehorizontal depth of cut line(previously drawn on the face of theworkpiece). When cutting hard orabrasive timbers it is advisable to cutto the full depth of the comb finger ina series of steps not exceeding 3mm.After cutting the joint, the cutter can

be lowered to the line for a finaltrimming cut, or slightly below it toallow for finishing.

Cutting the JointConnect the router and switch on.Cut between each pair of fingers,working from left to right. Repeat thecutting operation on each end of eachbox side. To ensure correctly fittingand mirrored joint is obtained bothleft-hand and right-hand edge guidesshould be used.

Checking the fitAssemble the joints dry to check thefit before cutting the grooves for thetop and bottom of the box or cabinetcarcass. Remember that the groovesto take the base and top panels (i.e.thin plywood base and/or rebatedthicker panel), will show on the faceof the box on two sides unless theyare cut as stopped grooves.

Using a home made jigA simple home-made jig can be easilymade from MDF and softwood off-cuts. This can be used with any sizerouter fitted with a suitable guidebush (for example a 16mm guide bushand a 6mm diameter two flutecutter).

The fixed batten shown on theunderside of the jig matches thecomb joint width precisely, in orderto space out the fingers on eachsubsequent pass. A slot in the jigallows the guide bush to trackprecisely in order to cut each slot inturn.

Secure both pieces of woodplus a backing piece in thejig (the offset must matchthe cutter diameter exactly).Set up the router with the guide bush and straight cutter and cut the first finger.

Insert the template batteninto the first slot andmachine the second.Repeat this procedure foreach subsequent pass until allthe fingers have been cut. Checkthe joint before turning them over(end to end - otherwise the top andbottom edges won’t align flush). IP

John Perkins adds an additional feature,in the form of an inverted router table,to his dedicated routing bench.

An inverted or overhead tableis one of the most importantaccessories for the router,

offering far greater scope in handlingmaterial, as well as giving the fullrange of router cutters. It is also byfar easier and safer to carry out manyrouting operations with the routerrigidly mounted and by feeding thematerial into the cutter, against afence and on a flat table. Also, as thetable, cutter and fence will alwaysremain square to each other, accuracycan be assured.

In our first issue of INProfile (Issue 1Winter 1997 pages 22-25 ) wefeatured a dedicated routing bench,that could be easily made in theworkshop and that would form arouting centre to support a widerange of routing operations. In thisissue we suggest ways ofincorporating both inverted andoverhead routing facilities in the same routing centre.One of the many benefits afforded bymaking your own routing bench, isthat it can be of a size to suitboth one’s ownrequirements andthe availablefloor

space.

Inverted routing When making any routing jig or tableit is important to keep it simple, bothin its construction and its use. Forsimplicity and reliability, it is worthconsidering using proprietaryproducts such as those from theTrend range of jig-making accessories.These include mounting plates,threaded inserts, lever handles andknobs, and items from theirRouterack Range. A bonus is thatthe Routerack universal stand setoffers many possibilities for mountingthe router over the bench.

Mounting the routerOne of the main problems inconstructing any routing table is inthe method of attaching the router,to both ensure that it is secure andrigid and to minimise the loss in thedepth of cut due to the thickness ofthe mounting plate.

Mounting platesThere are various methods of makingmounting plates, although it is often

better to buy ready drilled platessuch as the CRT insert

plate. This is availablepre-drilled to suit

most popular routers.For ease of fitting and

cutter changing, the tableaperture should ideally belarge enough to allow therouter to pass through.

Bench cut-outOn 6mm MDF or plywood, mark outa rectangle equal in size to themounting plate. Draw a line 12mm infrom the edges of the rectangle andcut out to form a template. Positionthis template on the bench centring itacross the top and square to thefront edge. With a jigsaw cut out thecentral portion leaving a 1.5mm gapto the inside line. Use a bearingguided straight flute cutter to trimthe edge, whilst following thetemplate and a 12mm bearing rebatecutter to form a rebate around thecut-out equal in depth to thethickness of the plate. Check thatthe plate fits, trimming the edge ofthe rebate to form a sliding fit withno side movement.Fit the router plate and check that itis level with the bench surface. Ifpreferred, cut the rebate slightlydeeper and either apply metal orplastic shims to the rebate face, oruse adjustable screws as supplied in

by John Perkins

under and over

routing workshop


Plates can be made from variousmaterials such as polycarbonatesheet, aluminium or solid plastic.Here the Trend CRT plate is set intoa thicker table plate to allow therouter to be lifted through the table.

Dust extractioncollection boxmade from 6mmplywood lid with8mm hardwoodsides

Locking handlefor positioningfences

Dust extractionnozzle fittedthrough end ofdust box

Cut 10mm slots parallel to end offence to take locking levers

Cutter aperture cut65 x 75mm wide x75mm high in eachfence face

Adjustment bolt &nut for setting cutteraperture betweenfalse faces

Sliding hardwood false faces withrecessed slots to take locking bolts

Fence cut from 8mm plywood or MDFwith 750 x 225mm face and 750 x 125faces glued together to form right angle

A simple fencecan be madefrom plywoodand fitted with

adjustable faces.

Illustration showingself-made plate forinserting in rebatedslot in table.


dovetailcompetitionPlease send in any unusual examples of workmade with a Dovetail Jig. We shall feature the bestsamples in the next issue of INProfile. Trendproducts to the value of £100 will be awarded forthe most innovative design.

Send all entries to:Dovetail Designs TrendFREEPOST Penfold Works Imperial WayWatford WD2 4WD

All entries will be returned. Good photographs and transparencies will be accepted.Closing date 11th January 1999.

routerlathecompetitionwinnerIn our first edition ofINProfile we offered a prizeof Trend products to thevalue of £100 for the bestand most innovativeexamples of work turned onour Routerlathe.

John Pike from Winchesterin Hampshire sent in thisattractive octagonal planterstand with ornate spiralcarving, cove fluting andradial rings.

John used a contourtemplate to create a taperedcolumn in conjunction withthe spiralling facility of theRouterlathe, resulting in aninteresting irregular fluteprofile and attractive handcarved texture.

the Trend Levelling Kit.

Overhead routingMost makes and models of routerscan be mounted above the benchusing the Trend Routerack universalstand. To support the stand pillar, drilla 40mm hole through the bench topapproximately 120mm from the rearedge. Turn the bench top over andmark the position of the pillar basemounting holes around it. Drill theholes to take M10 bolts, recessing theheads flush into the top face. Boltthe pillar base to the underside of thebench top.Follow the mounting instructions formounting the router on the pillar,either using the clamping bracketassembly, or a tool plate for routerswith 43mm or 60mm mounting

collars (ref. RR21 & R22).

Back fenceA simple back fence can be madefrom Medium Density Fibreboard(MDF) or plywood. This must bedesigned to cover the back of thecutter or incorporate a cutterguard.Two slots are cut in the baseboardto allow the fence to be alignedwith the cutter using adjustablelevers fitted with large washersscrewed into captive threadedTeenuts (PTN10/10).It is advisable to fit a dust extractionport to the fence for connection toa vacuum extractor. In use, therouter plate is held down by theback fence. IP

Some more samples areshown here to illustrate thehigh standard of entries sent.The first two pieces aremade by: Bruce Boulter andthe last two pieces made by M Baggs.

direction of the cutter is used to pull the cutter into the timber. Thisensures that the fence is also pulledinto the edge of the material. If fed in the opposite direction, the fencewill tend to wander away from theedge leaving an irregular widthmoulding and making it more difficultto maintain a smooth and even feedspeed. Also, there is the risk of therouter running away from youcreating a safety hazard.

Inverted routingWhen routing on a table, that is withthe router mounted beneath it, thefeed direction is always from right toleft (against the face of the fence).This ensures that the workpiece ispushed by the cutter against the tablefence. If you attempt to feed fromthe opposite end, the workpiece willbe pulled away from you. Not onlywill you not be able to machine thework successfully but you are likely tobe set off balance, againsetting up a safety hazard.

Overhead RoutingWhen using an overhead router, thefeed direction should always be fromleft to right. Again the rotationaldirection of the cutter will pull theworkpiece against the fence face.Feeding in the opposite direction willcreate an unsafe and unworkablesituation as before. IP

whichdirection?

Follow this feed direction when using the router as a hand held machine (i.e. fromleft to right)

Workpiece securely clampedto bench or held byvacuum chuck

Base of router usingeither a bearing guidedcutter or a side fence

Rotational directionof cutter

Inverted router table

Workpiece

Push stick

Table fence

Rotational direction ofcutter forces workpieceagainst fence

Feed direction

Table

Workpiece

Push stick

Fence

Feed direction

Of all the queries that the Trend technical supportreceive during the course of the year, the most commonrelate to confusion over the correct feed direction whenusing both hand-held or table mounted routers.


A

B

For hand heldrouter, feed leftto right.

For router table,feed materialright to left.

For overheadrouting, feedleft to right.

One of the most importantrules of routing is feeddirection. This refers to

the direction in which the workpieceis fed across the face of the cutter,or the cutter across the workpiecein relation to the rotation of thecutter. The golden rule is that for allrouting operations the feed directionshould oppose the rotationaldirection of the cutter.

What is important to remember isthat when the router is above the cutter, shank pointing upwards,the cutter is rotating clockwise whenviewed from above (see A). Whenthe motor is beneath the cutter withthe cutter shank pointingdownwards, the rotational directionof the cutter is anti-clockwise whenviewed from above (see B).

Hand-held routingWhen using the router as a handheld machine for edge rebating,planing or moulding, the rotational

Jig making is an essential part of routingand for repetitive operations offerssavings on both time and productivity.

One example of this is shown by making asimple jig for cutting a lock mortise and theshallow recess to take the lock face plate.

When fitting a number of locks of the sametype and size, the jig can be fairly simple.However, a more sophisticated jig can bedesigned to accommodate different lock anddoor sizes.

The Trend mortising cutter (Ref. 5/52) is ideal,having a plunge cutting depth of almost 70mmand good chip clearance characteristics toremove waste material quickly. If a deepermortise is required, a chisel or drill bit can beused to increase the depth.


by Miles Davey

Please note: Before cuttingthe mortise and face platerecess, work out the marginbetween the outside diameterof the guide bush and theoutside diameter of the cutter.Margin Formula = Deductdiameter of cutter fromoutside diameter of guidebush and divide by 2.

2on-sitetechniques for the trade

Materials for making the jig

Template Face 1 x 1/2” x 350 x 190mm MDFCheeks 2 x 18 x 350 x 210mm MDFMachine screws 4 x M6 x 16mm panheadThreaded inserts 4 x M6 for wood

A simple jig for mortise Locks

The template face is secured to the jigcheeks using machine screws and threadedinserts. The recessed slots are cut parallelto the top and bottom and allow thecheeks to be set to suit any doorthickness. The length of the slots togetherwith the notched sides of the templateface give sufficient clearance for the routerbase when routing the key slot and spindlehole.

The cheeks have apertures toaccept the same diameterguide bush to rout the key slotand spindle holes on eitherdoor face. The jig cheeks arewide enough to support therouter for this purpose.A 38mm x 134mm slot

is required. This willenable the face plate tobe routed with a 1/2”cutter and a 26mmguide bush. By insertingtwo packing pieces, oneat each end of the slot,a 32mm guide bush canalso be used to rout themortise.

Generally a mortise lock body isaround 19mm thick, with a faceplate width of 25mm.

Routing the MortisesCentre the jig across the door edge and secure itusing Gripper clamps.

Insert the packing pieces into each end of theslot, and with the larger guide bush fitted, routthe mortise first. Cut in a series of shallow steps,re-setting the depth of cut for each.Cut to the full depth of the lock body plus extradepth to allow for the recess for the face plate.Then remove the packing pieces, fit the smallerdiameter guide bush and cut the shallow face

plate recess. Carefully square the corners of themortise and recess using a sharp chisel.

Still using the same combination of cutter andguide bush rout the hole for the handle spindleand the slot for the keyhole.

Nestling amidst thetranquil surroundingsof the Peak National

Park lies an oasis forwoodworkers in the

shape of CraftSupplies. Alreadyboasting a wellstockedshowroom, craft

gallery and referencelibrary, Craft Supplies provide

several courses including furnituremaking, lathe turning and routing at the‘Academy’ located on site.To assist with this case study I went ontheir two day routing course.

I arrived at Milne House, (residentialaccommodation) Millers Dale, theevening before and soon becameacquainted with others on the course allof whom had different careers andbackgrounds yet shared an interest inwanting to learn about the art of

routing.Our first day started with a heartybreakfast before making our way nextdoor to the ‘Academy’ where we weregreeted by our lecturer Bob Lambertwhose career of furniture making andjoinery compliments his ability andexpertise in routing. Initially Bob dealtwith all the safety issues, router features,

the importance of router, collet andcutter care and types of cutters. Hisprogression was dictated by theunderstanding and confidence of hisstudents and led to table routing, hand-held routing and the advantages of jigsand templates.

Craft Supplies have cleverly chosen theproduction of a dressing table mirrorand drawer assembly as their project forthe course, incorporating as many basicand advanced routing techniques as theproject will allow. By the end of the firstday we had planed the edges of ourmaterial, and produced our drawer andhousing consolidating the CraftsmanRouter Table and the Dovetail Jig.

At the end of a productive and enjoyableday we spent a pleasant evening in thelocal public house ‘The Anglers Rest’.

The second day introduced rebating andthe Mini Ellipse Jig with which we

produced the oval mirror. By lunchtime our project was complete leaving theremainder of the day for the lecturer toconcentrate on the particular needs ofthe students and/or their weaknessesdemonstrating the extensive use of theCraftsman Router Table, the ClampGuide and the Routerlathe.

This is a thorough course which offersplenty of hands-on routing andprofessional tuition. It is good value formoney and provides excellent food andaccommodation...highly recommended!

COURSE DETAILS:

Two day basic course available. Courseincludes table, Dovetail Jig and Ellipse Jigtechniques.

COURSE PRICE:

Two Day Basic ______ £150

The Mill, Millers Dale, Nr Buxton, DerbyshireSK17 8SN Tel: 01298 871636 Contact:Eve Middleton Lecturer: Bob Lambert

Dressing table topdrawer and mirrormade on the Craft

Supplies course

the routway to do it!

Producinghousings for

drawer frame

Assemblingthe dovetailed

drawer

Forming the mirror frame with theMini Ellipse Jig

Completed mirror frame

Assembling mirror frame brackets

INProfile sent Trend Technical Team member Tom Rogers alongto Craft Supplies to review the two day routing course.


Course Details:

Two day basic course and two dayadvanced course available. Projectbased - produces table as shown

Course Prices:

Two Day Basic________ £150

Two Day Advanced ____ £150

Selling Road, Macknade, Faversham, Kent ME13 8XF Tel: 01227 373297 Contacts: Roy Sutton/John Farrington

Crewe Toll, Edinburgh, EH4 2NZ Tel: 0131 332 2491 Ext. 2229 Contacts: Stuart Telford/Derek Brown

EDINBURGH’S TELFORD COLLEGE

WOODCRAFTTRAINING

50 West Street, Isleham, Nr Ely,Cambridgeshire CB7 5SB Tel: 01638 780978 Contact: Mike Humphrey

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

NORTHERN CRAFTS& POWER TOOL CO.

YANDLESWOODWORKINGCENTRE

OAKLANDS COLLEGESchool of Construction

St Peters Road, St Albans, Herts AL1 3RXTel: 01727 737213 Contact: Jeanne O’Reilly

Hurst Works, Martock, Somerset TA12 6JUTel: 01935 822207 Contacts: Beverley Mansfield/Ann Pain

routing coursesA guide to our sponsored routing courses in the UK

AUSTIN EAMES

Plas Acton Precinct, Pandy Lane,Wrexham, Clwyd, LL11 2UBTel: 01978 261095 Contacts: Peter or Richard Eames

WOODWORKING

AUSTIN EAMES

JOE GREENERS

HIREPLACE

Valley Street North, Darlington, Co. Durham,DL1 1PZ Tel: Freephone 0800 7312145 Contacts: Joe or Andy Greener

FREE £25 voucherfor all course studentsRedeemable towards the cost of any products sold by Northern Craft & Power Tool Co. Ltd

Course Details:

One day basic - intermediate courseand one day advanced coursesavailable. Course includes hand-heldtechniques and table routing.

Course Prices:

One Day Basic ________ £55

One Day Advanced ______ £55

Course Details:

One day basic - intermediate course available.Course includes hand-held techniques andtable routing.

Course Prices:


Course Details:

One day basic - intermediate and two dayadvanced courses available. Coursesinclude table routing, carving andproducing panel doors.

Course Prices:



Course Details:

One day basic - intermediate andone day advanced courseavailable. Course includes hand-held techniques, table routingand jig and template work.

Course Price:

One Day Basic £70

One Day Advanced £70

Course Details:

One day basic - intermediate courseand two day advanced course available.Course includes table and Routerlathetechniques.

Course Price:



Course Details:

Three one day courses available: basic -intermediate, advanced and trade.Course includes table routing,

Routerlathe techniques and using bothPostform Worktop and Hinge jigs.

Course Price:

One Day ________ £75

ROY SUTTON’SRouting Courses at theApple Craft Centre

NEATH COLLEGEDwr-y-felin Road, Neath,WalesTel: 01639 634271 Contacts: Dylan Wyn James/Wyn Pritchard

Course Details:

One day basic - intermediate courseand two day advanced coursesavailable. Course includes table,Routerlathe and Carver techniques.

Course Prices:



Course Details:

Two day basic - intermediate courseavailable. Course includes safety, routerand cutter maintenance and techniques.

Course Price:

Two Day Basic ________ £65

Octacut® Eight in One SetThese new sets have beendesigned to cut eight differentprofiles: four ovolo, tworounding overs, one covemould and one rule joint.Three sizes are offered withradii of 6.3mm (25/3x8mmTC),9.5mm (25/5x8mmTC) and12.7mm (25/7x1/2TC).

Panel & VeiningA range of three 1/4” shank small sizedpanelling cutters which are also idealfor veining and fluting applications.They are ideal for use with theRouterlathe. The 16/2 has a radius of4.8mm and the 16/3 and 16/4 have aradius of 6mm and 7.5mm respectively.

Straight Two FluteThe C153x1/2TC is a new longreach 1/2” diameter straightcutter added to the CraftRange. It has a cut lengthof 50mm and can be usedwith Trend’s PostformWorktop Jigs to cut,butt and scribe joints.

Easyset® - Profile ScribersThese Profile Scribers use the same componentsas our standard PSC sets. Both parts of the jointare cut by only changing the cutter height with nore-assembly of parts required.The three 1/2” shank styles offered are ogee -(PSC/101), flat classic - (PSC/103) and bevel -(PSC/105). The ogee set is also available in thecraft range with an 8mm shank (C155).

Ovolo Panel Moulder A new size introduced to completethe range of ovolo cutters. The7/10x1/4TC can be used for panelcutting of drawer fronts as well asedging window frames, glazing bars,cabinets, table-tops, shelves and firesurrounds. It has a radius of 4mmwith a diameter of 19mm.

Dished Mould RadiusThe 18/15x1/4TC dished mouldis an ideal panelling cutter forkitchen or cabinet doors, andfor ribbon twist on therouter lathe. It has aradius of26mm and adiameter of32mm.

Cutter Set SS7Developed from the highly successful SS3 set, this affordable set contains

six popular 1/4” shank cutters, comprising a 6mm and 12mm straighttwo flute, a 90° v-groove, two ball-bearing guided ovolo round overs,

(R6.35mm and R9.5mm) and one bearing guided ogee cutter.

cuttersnew

90° Guided TrimmerWith a 9.5mm diameter and a 25mmcut length, the 90° TrimmerT46/02x1/4TC is a useful sizetrimming cutter for laminate andtemplate trimming operations.

inprofile 2

Documents

new catalogue

trend waveformsawblades

new t5variable speed

trend stockist

industrial sawblade

presentjim phillips

restneil mcmillan

launch of thenew t5