User manual | COMBI1002 Worktop Jig Instructions

COMBI 1002
Please read these instructions before use.
COMBI 1002
Dear Customer
TECHNICAL DATA
Thank you for purchasing this Trend product,
we hope you enjoy many years of creative and
productive use.
Jig thickness
Cutter size
Guide bush size
Workpiece thickness max.
Worktop width
min.
max.
Weight
Please remember to return your guarantee card
within 28 days of purchase.
CONTENTS
TECHNICAL DATA ____________________ 1
16mm
12.7mm
30mm
45mm
450mm
1000mm
9.6kg
SAFETY ___________________________ 2-3
ITEMS ENCLOSED _________________ 4
DESCRIPTION OF PARTS ______________ 5
ACCESSORIES
– Recommended Cutters _______________ 6
– Clamps ____________________________ 6
The following symbols are used throughout this
manual:
– Sub-base Sets & 30mm Guide Bush _____ 7
– Panel Connector Bolts ________________ 8
Denotes risk of personal injury, loss of
life or damage to the tool in case of nonobservance of the instructions in this
manual.
– Biscuit Jointer for the Router ___________ 8
– Carry Case _________________________ 8
– Bolt-on Clamps ______________________ 9
ASSEMBLY
Refer to the instruction manual of
your power tool.
– Location Bush Identification ___________ 10
– Margin Distance ____________________ 10
This unit must not be put into service until it has
been established that the power tool to be
connected to this unit is in compliance with
2006/42/EC (identified by the CE marking on the
power tool).
– Setting Out the Joints ________________ 10
OPERATION
– Setting the Length Stop for Female Cut _ 11
– Female Joint _______________________ 12
– Male Joint _________________________ 13
INTENDED USE
– Out-of-Square Joints ______________ 13-14
This jig is intended for use with a plunge router
with suitable guide bush and router cutter fitted
to rout a kitchen joint in laminate covered particle
board.
– Cutting the Bolt Recesses ____________ 15
– Strengthening/Sealing the Joint ________ 16
– Corner Radius & 22.5° Mitre Joint ______ 17
– Curved Peninsular __________________ 18
– 45° End Cut _______________________ 19
%
– Cable Tidy Inserts & 35mm Circular Hinge _ 20
– Cutter/Guide Bush Concentricity Checker __ 21
MAINTENANCE _____________________ 21
ENVIRONMENTAL PROTECTION
& GUARANTEE _____________________ 21
SPARE PARTS
– Spare Parts List ____________________ 22
– Spare Parts Diagram ________________ 23
TROUBLE SHOOTING ________________ 24
-1-
If you require further safety advice,
technical information or spare parts,
please call Trend Technical Support
or visit www.trend-uk.com
COMBI 1002
SAFETY
WARNING:
Observe the safety regulations in the
instruction manual of the power tool
to be used. Please read the following
instructions carefully. Failure to do so
could lead to serious injury. When using
electric tools, basic safety precautions,
including the following should always be
followed to reduce the risk of fire, electric
shock and personal injury. Also observe
any applicable additional safety rules.
Read the following safety instructions
before attempting to operate this product.
PLEASE KEEP THESE
INSTRUCTIONS IN A SAFE PLACE.
The attention of UK users is drawn
to The Provision and Use of Work
Equipment Regulations 1998, and any
subsequent amendments.
power tool or accessory by cord or
covering to contain long hair.
pull it to disconnect from the socket.
5. Consider working environment. Do
Keep cord from heat, oil and sharp
not use the product in the rain or in
edges. Always trail the power cord
a damp environment. Keep work
away from the work area.
area well lit. Do not use power tools
18. Connect dust extraction equipment.
near gasoline or flammable liquids.
If devices are provided for the
Keep workshop at a comfortable
connection of dust extraction and
temperature so your hands are
collection facilities, ensure these are
not cold. Connect machines that
connected and properly used.
are used in the open via a residual
current device (RCD) with an
19. Check all fixing and fastening nuts,
actuation current of 30 mA maximum.
bolts and screws on power tool,
Use only extension cables that are
attachment and cutting tools before
approved for outdoor use.
use to ensure they are tight and
secure. Periodically check when
6. The accessory or attachment must
machining over long periods.
be kept level and stable at all times.
7. Keep work area clean. Cluttered
workshops and benches can cause
injuries. Ensure there is sufficient
room to work safely.
8. Secure idle tools. When not in use,
Users should also read the HSE/HSC
tools should be stored in a dry and
Safe Use of Woodworking Machinery
high or locked up place, out of reach
Approved Code of Practice and Guidance
of children.
Document and any amendments.
9. For best control and safety use
Users must be competent with
both hands on the power tool and
woodworking equipment before using our
attachment. Keep both hands away
products.
from cutting area. Always wait for the
IMPORTANT NOTE:
spindle and cutter to stop rotating
before making any adjustments.
Residual Risk. Although the safety
instructions and operating manuals for
10. Always keep guards in place and in
our tools contain extensive instructions
good working order.
on safe working with power tools, every
power tool involves a certain residual risk 11. Remove any nails, staples and other
metal parts from the workpiece.
which cannot be completely excluded
12. Maintain tools and cutters with care.
by safety mechanisms. Power tools
Keep cutters sharp and clean for
must therefore always be operated with
better and safer performance. Do
caution!
not use damaged cutters. Follow
General
instructions for lubricating and
changing accessories. Keep handles
1. Disconnect power tool and
dry, clean and free from oil and
attachment from power supply
grease.
when not in use, before servicing,
when making adjustments and
13. Maintain accessories. Do not use
when changing accessories such
damaged accessories. Only use
as cutters. Ensure switch is in “off”
accessories recommended by the
position. Always ensure cutter has
manufacturer.
stopped rotating.
14. Check damaged parts. Before
2. Always mount the power tool,
operation inspect the attachment,
accessory or attachment in
the power tool, the cable, extension
conformity with the instructions. Only
cable and the plug carefully for signs
use attachment and accessories
of damage. Check for alignment of
specified in the power tool manual.
moving parts, binding, breakage,
The tool or attachment should not be
mounting and any other conditions
modified or used for any application
that may effect its operation.
other than that for which it was
Have any damage repaired by an
designed. Do not force tool.
Authorised Service Agent before
using the tool or accessory. Protect
3. Keep children and visitors away. Do
tools from impact and shock.
not let children or visitors touch the
tool, accessory or attachment. Keep 15. Do not use tool if switch does not
children and visitors away from work
turn it on or off. Have defective
area. Make the workshop child proof
switches replaced by an Authorised
with padlock and master switch.
Service Agent
4. Dress properly. Do not wear loose
16. Don’t over reach. Keep proper
clothing or jewellery, they can be
footing and balance at all times. Do
caught in moving parts. Rubber
not use awkward or uncomfortable
gloves and non-skid footwear
hand positions.
is recommended when working
17.
Don’t abuse the cable.Never carry
outdoors. Wear protective hair
-2-
20. Stay alert. Watch what you are
doing. Use common sense. Do not
operate tools when you are tired,
under the influence of drugs or
alcohol.
21. Personal Protective Equipment
(PPE) for eye, ear and respiratory
protection must be worn. All PPE
must meet current UK and EU
legislation.
22. Do not leave tools running
unattended. Do not leave tool until it
comes to a complete stop.
23. Always clamp workpiece being
machined securely.
24. Only use cutting tools for
woodworking that meet EN8471/2 safety standards, and any
subsequent amendments.
25. Vibration levels. Hand held power
tools produce different vibration
levels. You should always refer
to the specifications and relevant
Health & Safety Guide.
Routing Safety
1. Read and understand instructions
supplied with power tool, attachment
and cutter.
2. Keep hands, hair and clothing clear
of the cutter.
3. Remove adjusting keys and
spanners. Check to see that keys
and adjusting spanners are removed
from the router tool, cutter and
attachment before turning router on.
Make sure cutter can rotate freely.
4. Noise. Take appropriate measures
for the protection of hearing if
the sound pressure of 85dB(A) is
exceeded. Routing sound pressure
may exceed 85dB(A), so ear
protection must be worn.
5. Eye protection. Always wear eye
protection in the form of safety
goggles, spectacles or visors to
protect the eyes.
6. Respiratory protection. Wear a
face or dust mask, or powered
respirator. Dust masks/filters should
be changed regularly.
COMBI 1002
surfaces are cleaned to remove dirt,
7. Do not switch router on with the
grease, oil and water.
cutter touching the workpiece. At the
end of the cut, release the router
10. Observe the correct assembly and
plunge and allow spindle to stop
fitting instructions in the router
rotating. Never use the spindle lock
instruction manual for fitting the
as a brake
collet, nut and cutter.
8. The direction of routing must always 11. Tool and tool bodies shall be
be opposite to the cutter’s direction
clamped in such a way that they will
of rotation. Do not back-cut or climbnot become loose during operation.
cut.
Care shall be taken when mounting
cutting tools to ensure that the
9. Check before cutting that there
clamping is by the shank of the
are no obstructions in the path of
cutting tool and that the cutting
the router. Ensure there are no
edges are not in contact with each
obstacles beneath workpiece when
other or with the clamping elements.
cutting full thickness, and that a
sacrificial work surface is used.
12. It is advisable to periodically check
the collet and collet nut. A damaged,
Router Cutter Safety
worn or distorted collet and nut can
1. Cutting tools are sharp. Care should
cause vibration and shank damage.
be taken when handling them. Do not
Do not over-tighten the collet nut
drop cutters or knock them against
13. Do not take deep cuts in one pass;
hard objects. Handle very small
take several shallow or light passes
diameter cutters with extra care.
to reduce the side load applied to the
Always return cutter to its packaging
cutter and router. Too deep a cut in
after use.
one pass can stall the router.
2. Always use cutters with a shank
diameter corresponding to the size of 14. In case of excessive vibrations whilst
using the router stop immediately
the collet installed in your tool.
and have the eccentricity of the
3. The maximum speed (n.max) marked
router, router cutter and clamping
on the tool, or in instructions or on
system checked by competent
packaging shall not be exceeded.
personnel
Where stated the speed range shall
15. All fastening screws and nuts should
be adhered to. Recommended
be tightened using the appropriate
speeds are shown in the Trend
spanner or key and to the torque
Routing Catalogue and/or website.
value provided by the manufacturer.
4. Always use router cutters in a router.
16. Extension of the spanner or
Drill and boring bits must not be
tightening using hammer blows shall
used in a router. Router cutters
not be permitted.
must only be used for the material
cutting application for which they are 17. Clamping screws shall be tightened
according to instructions provided by
designed. Do not use on metal or
the manufacture. Where instructions
masonry.
are not provided, clamping screws
5. Never use cutters with a diameter
shall be tightened in sequence from
exceeding the maximum diameter
the centre outwards.
indicated in the technical data of the
powertool or attachment used.
6.
7.
Before each use check that the
cutting tool is sharp and free from
damage. Do not use the cutting tool
if it is dull, broken or cracked or if in
any other damage is noticeable or
suspected.
Using Routers In A Fixed Position
1. Attention should be made to the
HSE’s Safe Use of Vertical Spindle
Moulding Machines Information
Sheet No.18 and any revisions.
2.
After work, release the router plunge
to protect the cutter.
approximately hip height.
6. Use a No-Volt Release Switch.
Ensure it is fixed securely, easily
accessible and used correctly.
7. In router table (inverted) mode, stand
to the front right of the table. The
cutter will rotate anti-clockwise when
viewed from top so the feed direction
is from the right (against the rotation
of the cutter). In overhead mode,
stand to the front left of the machine
table and the feed direction is from
the left.
8. Do not reach underneath table or
put your hands or fingers at any
time in the cutting path while tool is
connected to a power supply.
9. Never thickness timber between the
back of the cutter and the backfence.
Useful Advice When Routing
1. Judge your feed rate by the sound
of the motor. Feed the router at a
constant feed rate. Too slow a feed
rate will result in burning.
2.
Trial cuts should be made on waste
material before starting any project.
3. When using some attachments e.g.
a router table or dovetail jig, a fine
height adjuster is recommended.
4. When using a template guide bush,
ensure there is sufficient clearance
between cutter tip and inside edge
of bush and that it cannot come into
contact with collet and nut. Ensure
cutter and guide bush are concentric.
Router Cutter Repair/Maintenance
1. Repair of tools is only allowed in
accordance with the manufacturers
instructions.
2. The design of composite (tipped)
tools shall not be changed in process
of repair. Composite tools shall be
repaired by a competent person i.e.
a person of training and experience,
who has knowledge of the design
requirements and understands the
levels of safety to be achieved.
3. Repair shall therefore include, e.g.
the use of spare parts which are in
accordance with the specification
of the original parts provided by the
manufacturer.
Cutters should be kept clean. Resin
3. Always use a push-stick or pushbuild up should be removed at
block when making any cut less than
regular intervals with Resin Cleaner.
300mm in length or when feeding the 4. Tolerances which ensure correct
The use of a PTFE dry lubricant will
clamping shall be maintained.
last 300mm of the cut.
reduce resin build up. Do not use
PTFE spray on plastic parts.
5. Care shall be taken that regrinding
4. The opening around the cutter
of the cutting edge will not cause
should be reduced to a minimum
8. When using stacked tooling (multiweakening of the body and the
using suitably sized insert rings in
blade, block and groover etc.) on a
connection of the cutting edge to the
the table and closing the back fence
spindle arbor, ensure that the cutting
body.
cheeks
or
fitting
a
false
fence
on
the
edges are staggered to each other to
back fence.
reduce the cutting impact.
Version 7.2 06/2013
5. Whenever possible use a work
9. Cutter shanks should be inserted
holding
device
or
jig
to
secure
into the collet all the way to the line
component being machined. Ensure
indicated on the shank. This ensures
any attachment is securely fitted to
that at least 3⁄4 of the shank length
the workbench, with table surface at
is held in the collet. Ensure clamping
-3-
COMBI 1002
ITEMS ENCLOSED
x1
x3
x1
x1
x1
x1
x1
x1
ITEMS REQUIRED
n 1/2” plunge router.
n 30mm guide bush.
n 12.7 diameter x 50mm cut router cutter with
1/2” shank.
n Trestle x 2.
n 100mm throat clamp x 2.
n Hand tools.
n Panel connector bolts.
n Wooden biscuits size No.20.
n Sealant.
-4-
COMBI 1002
DESCRIPTION
OF PARTS
E&F
S
J
I
I
V
AB
B
I
AA
R
G
C
H
G
H
P
G
E&F
D
S
U
V
U
A AC
D
T
V
AC
W
U
Y
D
R
X
Z
R
Q
M
N
L
A
Jig body
B
Label
C
Postform joint slot
D
Female joint bush location hole
O
K
E
Length setting stop location hole
F
Male joint bush location hole
G
Accessary bolt on clamp holes
Q
Corner radius slot
H
Length stop fixing holes
R
Corner radius bush location hole
I
Bolt recess bush location hole
S
22.5° Mitre joint bush location hole
J
Connecting bolt recess slot
T
Curved peninsular slot
K
Alloy location bush
U
Curved peninsular bush location hole
45° End end cut bush location hole
L
Length setting stop
V
M
Length setting stop bolt
W
Cable tidy 60mmØ
N
Length setting stop washer
X
Cable tidy 80mmØ
O
Length setting stop knob
Y
Cable tidy rectangle
P
Colour dot locations
Z
35mm circular hinge recess
-5-
AA
Guide Bush / Cutter
Checker
AB
35mm Hole for
3/4 BSP mixer tap
AC
25mm Hole for
bridge (bed) mixer
tap at 180mm centre
COMBI 1002
ACCESSORIES
Please use only Trend original accessories.
Recommended Cutters
A 12.7mm (1/2”) diameter cutter must be used, which
has a 50mm cutting reach and plunge cut facility.
Router must be plunged in stages of maximum 8mm
in one pass.
Ref. 3/83X1/2TC, 3/83DX1/2TC, TR17X1/2TC,
TR17DX1/2TC, C153X1/2TC, C153DX1/2TC
Ref. RT/11X1/2TC
Description
RT/11 Spare blades
Order Ref.
RB/A (1 off)
RB/A/10 (10 off)
Description
RT/13 Spare blades
Order Ref.
RB/H (1 off)
RB/H/10 (10 off)
Ref. RT/13X1/2TC
Clamps
Ref. FC/200
Two heavy duty quick action or gripper clamps
are required to secure the jig to the worktop.
100mm (4”) min.
throat depth
Two heavy duty quick action or gripper
clamps with throats of at least 100mm
(4”) are required to secure the jig to the
worktop. Whenever fast action clamps are
used, ensure they do not foul the router
path and that they are securely tightened.
-6-
COMBI 1002
Sub-base Sets
Ref. UNIBASE
To obtain a perfect accurate close fitting joint, a
30mm guide bush must be used. The guide bush
must always be fitted concentric with the cutter.
This can be achieved using Trend sub-bases and
30mm outside diameter guide bush ref. GB30.
Trend sub-bases have a central recess to allow
fitting of the Trend guide bush to most makes of
routers and are available ready to fit the most
popular makes.
Two types are offered GB/5 and UNIBASE.
All sub-bases contain screws, a line up bush
and pin. The line up pin and bush ensure exact
alignment of sub-base with router spindle, when
fitted with the relevant collet.
Fits following router models
Atlas Copco OFSE2000 Bosch GOF 1300ACE, 1600A,
1700ACE Casals FT2000VCE DeWalt DW625EK,
629 Draper R1900V Elu MOF 31, 77, 98, 131, 177(E)
Felisatti TP246(E), R346EC Festo OF2000E Freud
FT2000E Hitachi M12V, M12SA, TR12 Makita 3612BR,
3612(C) Metabo OF1612, OFE1812 Performance Pro
CLM1250R >11/2003, CLM2050R Ryobi RE600N, R600N,
RE601, R500, R502 Skil 1875U1 T-TECH TT/R127
Wadkin R500
General instructions for fitting
Sub-bases to Router
1. Fit line up guide bush onto sub-base, with
screws supplied.
2. Fit 12.7mm (1/2”) shank line up pin into collet
of router. Plunge router until pin projects
through base and lock plunge.
3. Locate guide bush and sub-base assembly
over protruding pin.
4. Line up fixing holes and fit screws.
5. Now tighten up screws.
6. Remove line up bush and line up pin.
Alignment should now be correct. Fit 30mm
guide bush and cutter.
7. Periodically check the sub-base is concentric
to the spindle of the router.
30mm Guide Bush
Ref. GB30
-7-
COMBI 1002
Panel Connector Bolts
Ref. PC/10/M (Pack of 10)
Ref. PC/50/M (Pack of 50)
Ref. PC/100/M (Pack of 100)
Ref. PC/1000/M (Pack of 1000)
Panel butt connectors are essential for
connecting worktops. They fit into the recess on
the underside of the worktop and are tightened
with a 10mm spanner. The jig has integral bolt
recess slots to allow the bolt recess to be cut in
the underside of the worktop, using the standard
router cutter. The recess is elongated to allow
easy access for the spanner.
Biscuit Jointer for the Router
Ref. 342X1/2TC
Ref. TR35X1/2TC
Ref. C152X1/2TC
Worktops with inadequate support below them
need additional stability by biscuit jointing the
edges. The biscuit jointing set for the router
together with the No.20 biscuits will ensure
worktops do not sag or warp in time.
Flat Biscuit Dowels
Ref. BSC/20/100 (Pack of 100 biscuits)
Ref. BSC/20/1000 (Pack of 1000 biscuits)
Biscuits are used to strengthen the joint. When
used with PVA glue they expand ensuring a tight
joint.
No.20
Carry Case
Ref. CASE/1001
Hard wearing carry case for protection. Allows
easier transportation of the COMBI1002.
2
-8-
COMBI 1002
Bolt-on Clamps
Optional bolt-on clamps which fit directly onto
COMBI1002. Fixing Bolt Kits are required for
the clamps (1 off for PJ/CL/S and 2 off for
PJ/CL/L).
Ref. PJ/CL/S
Short Clamp for COMBI1002
(1 off required)
Ref. PJ/CL/L
Long Clamp for COMBI1002
(1 off required)
Ref. PJ/FBK
Fixing Bolt Kit for bolt-on clamps
(3 off required)
-9-
COMBI 1002
ASSEMBLY
Margin Distance
Location Bush Identification
Three location bushes are used in different holes
in the jig to align the correct template aperture
for the application.
Allow 8.5mm when cutting joints. Measure or
use a batten of this
thickness to aid
setting out.
Cutter
The holes are colour coded for easy
identification with dots as follows:
Green dot
Red dot
Blue dot
Yellow dot
Grey dot
White dot
Black dot
–
–
–
–
–
–
–
Guide bush
30mmØ
Female Joint
Male Joint
Mitre Corner
Connector Recess
45° Peninsular
Curved Peninsular
Corner Radius
Sub base
Template
Location
bush
Worktop
8.5mm
The jig has a colour coded key on its label for
quick reference.
Setting Out the Joints
When cutting a joint ensure location bushes
contact the postformed edge of the worktop. For
certain joints the worktop will need to be inverted
so that all cuts are made into the postformed
edge, never out through it. When routing worktop
the balancing paper on the underside may feather
edge – this feather edge should be removed with
abrasive paper.
Female
ring
Male
Location bushes are held in position by ‘O’ rings.
Insert the smallest end of the bush into the hole
by lightly pushing and turning at the same time.
If the bushes are tight use a lubricant on the ‘O’
ring. Ensure bushes are fully home before use.
When using jig ensure location bushes do not
foul workbench.
Right hand joint
Cut female with laminate up
Cut male with laminate down
Location bush
23mm
The joint takes up 23mm, this should
be allowed for with extra material in the
length of the male worktop.
Male
Postform edge
Female
PENINSULAR
Female
Postform edge
Postform edge
Male
Plan view
of joints
Female
-10-
Male
Postform edge
In order to prevent breakout of the
laminate, rotation of the cutter and
feed direction must always be into the
postform edge of the worktop.
Left hand joint
Cut female with laminate down
Cut male with laminate up
COMBI 1002
Setting the Length Stop for the
Female Cut
Carry out the setting operation first:
n Fit bushes into Green dot location holes
and offer the jig to the male worktop as
shown. Face marked Green dot must be
uppermost.
Setting the Length Stop
Postform edge
OPERATION
Length stop on
underside. Retained
with screw & knob
n Insert location bush in Red dot location
hole as shown, and position the jig across
the width of the male worktop. Loosely fit
the length stop (or adjustable long clamp).
n Fasten length stop (or adjustable long
clamp) to template so that it traps the
template across the worktop between the
Red dot location bush and the stop (or
adjustable long clamp). Tighten up the
knob.
n Remove the bush from Red dot location
hole. The template is now set to cut the
correct length of joint for the female cut.
n Some carcasses may have their backs
reduced which means in turn the worktop
width will be reduced. Please take this into
consideration when setting the length stop.
Location bushes
(Green dot)
Location bush
(Red dot)
Length Stop Arrangement
Jig
Worktop
Length stop
Washer
Knob
Set the length stop using the worktop
width for the male cut, as this may be
different to the female worktop width.
Using Adjustable Clamp Accessory
Ref. PJ/CL/L
Bolt
Jig
Ensure worktop is held secured to
trestles. Ensure jig is clamped
securely to worktop and placed at
a comfortable work height.
Worktop
Washer
Knob
PJ/CL/L Clamp
-11-
COMBI 1002
Female Joint
When cutting a joint, hold the router
guide bush hard against the template
and cut from left to right. It is
recommended that the depth stops of
the router are used to set the depths
of cut. Several shallow passes of
the router should be made and it is
not necessary to lean heavily on the
router or the jig. Allow the weight
of the router to rest on the part of
the template which is resting on the
worktop. Ensure router remains
parallel and upright at all times.
n Leave the two location bushes in holes
marked Green dot. (The Green dots must be
uppermost). Leave the length stop bush in
position.
n Place the template onto the worktop to
be cut, ensuring the location bushes are
touching the worktop. Now cramp securely in
position using two quick action clamps or the
accessory clamps ensuring they will not foul
the router path.
n Set cutter depth.
n Plunge router and cut joint in a series of
passes, feeding left to right. At the end of
each cut release plunge.
Routing the Female Part of the Joint
Ensure worktop position is
comfortable. Keep proper
footing at all times.
Quick action
clamp here
Router feed
direction
Postform
edge
Optional short clamp
PJ/CL/S on underside
-12-
Location bushes
(Green dot)
Length stop (or accessory clamp
PJ/CL/L) set for correct worktop
width on underside
COMBI 1002
Depending on accessibility lay female
worktop into position on units. Lay male
worktop on top and support other end.
Using a pencil draw round the female cut
onto the male. If inaccessible lay female
onto male. Depending on a right or left
hand joint, the pencil line may need to be
transferred on to the other side. Due to the
difference between the cutter and the guide
bush diameters, the cutter path (or cut line)
will be 8.5mm over from the edge of the
template, therefore either measure 8.5mm or
use a packing piece of this size to offset the
template by this amount to ensure the cutter
cuts along the pencil line.
Routing the Male Part of the Joint
Location
bushes
(Red dot)
The postformed edge of the worktop must
always be in contact with the location bushes,
this means that to cut a male right hand joint,
the worktop must be inverted. Remembering
to cut into the postformed edge.
Postform edge
Male Joint
Quick action
clamp here
Direction of
router travel
Optional accessory clamp PJ/
CL/L on underside, not used
as length stop
Optional accessory clamp
PJ/CL/S on underside
n Insert two location bushes into holes
marked Red dot. Face marked Red dot
must be uppermost.
n Remove the length stop (or adjustable
long clamp) from the female and fit to the
male side of template. Place template
across the width of the worktop and
tighten the knob. Now clamp securely to
worktop.
n Cut the male joint before finally cutting the
worktop to length. All cuts must be fed left
to right. At the end of each cut release
plunge.
Out-of-square Joints (max. 3°)*
It may not be possible to position all joints at
90°, in this case it is the male part of the joint
that has to be adjusted.
The length stop has a mitred end which is used
to set up for an out-of-square joint up to 3°.
To mark out an out-of-square joint, first lay the
female worktop on the cupboard carcass in its
correct position. Next lay the male section of the
worktop on the carcass and on top of the female
section of the worktop. Support the other end
of the male worktop. Using a pencil and from
underneath the worktop mark around the female
joint onto the male section of the worktop, if
access is difficult lay the female worktop onto
the male worktop, support other end and mark
with pencil from above. This drawn line is the
male joint cut line.
*Please Note:
Test fit the joints together, abrasive
paper may be required to clean up the
chipboard core.
Out-of-square joints are possible, but the
finished joint will not be as good as a 90° joint.
-13-
COMBI 1002
Setting Up Length Stop for Out-ofSquare Joints
n Insert both location bushes into Red dot
holes. Red dot face uppermost.
n Lay jig across the worktop, ensure the
location bushes touch the postform edge.
Clamp jig in position with quick action
clamps. Draw a line 8.5mm away from the
jig slot edge.
Quick action
clamp here
Location
bushes
(Red dot)
n With the mitred end of the length stop
facing towards the back of the worktop, as
shown. Fit the length stop onto underside
of jig by using the countersunk bolt,
washer and knob into one of the holes in
the jig. The bolt should be put into the
jig from above, do not tighten. Carefully
position the point of the length stop so that
it lines up with the 8.5mm margin pencil
line. When the correct position has been
obtained tighten bolt and knob sufficiently
to prevent length stop from moving.
Optional accessory
clamp PJ/CL/S on
underside
Parallel pencil line
8.5mm from jig slot edge
n Remove location bushes.
n Lay jig with length stop set onto male
work top that is to be cut. Allowing for
the 8.5mm margin and using the length
stop as a pivot point (pivot point on cut
line) position the jig so the jig slot edge is
parallel to the drawn pencil line. Re-check
positioning.
Direction of
router travel
8.5mm margin
pencil line
Cutting Male
Joint on Out-ofSquare Joints
n Clamp jig to worktop securely using quick
action clamps.
Quick action
clamp here
n Remove length stop and bolt assembly as
these are for setting up only and are not
required when routing
Shown exaggerated
n Set cutter depth.
n Plunge router and cut the male joint,
feeding left to right in a series of shallow
passes, feeding left to right.
Direction of
router travel
Male joint on
cut line
Jig slot edge 8.5mm away
from male joint cut line
After setting for out-of-square joint
the length stop must be removed or it
could come in contact with the router
cutter.
Male joint cut line
Pivot point on male
joint cut line
-14-
Cutting the Bolt Recesses
Setting Bolt Recess Length Stop
When the joint has been tested, proceed
as follows to cut the recess for panel butt
connectors on the underside of the worktop.
The same cutter and guide bush are retained
and used with the integral bolt recess slots in
the jig to produce the recesses for the panel
butt connectors.
Postform edge
COMBI 1002
Underside of worktop
Insert the location bushes into the Yellow dot
holes as shown.
n The template will need to be inverted when
cutting some bolt recesses. The jig has
three recesses at 200mm centres and a
fourth at 300mm centre, this allows three
bolts in 600mm wide worktops.
Postform edge
To set the length stop (or adjustable clamp)
for both joint recesses, insert a location bush
in Blue dot location hole as shown in diagram
and lay template across the width of the
worktop. The diagram shows for bolt recess in
Length stop (or accessory clamp
the male joint, Yellow dot holes up. Fit length
PJ/CL/L) on underside
Location bush
stop or adjustable clamp as before. Ensure
(Blue dot)
that the stops are against the rear of the
Routing the Bolt Recess in
worktop and not against the postform edge.
the Male Part of the Joint
Remove setting bush, and place template on
the underside of the worktop.
Underside of worktop
Quick action
clamp here
Length stop (or accessory clamp
PJ/CL/L) on underside
n Securely clamp jig to worktop.
n The bolt recesses should be
approximately 20mm deep although this will
depend upon the thickness of worktop. Set
the cutter depth.
n Repeat the set up procedure for the female
joint, however the location bush and length
stop (or adjustable clamp) should be fitted
on the opposite face of the worktop Yellow
dot holes down.
Worktop
Thickness
Depth
Recess
30
40
22mm
28mm
Best results are achieved
when the centre line of the bolt
corresponds to the centre line of
the worktop. Clamp jig securely
to worktop.
Direction of
router travel
Location bushes
(Yellow dot)
Routing the Bolt Recess in the
Female Part of the joint
Underside of worktop
Quick action
clamp here
Length stop (or accessory
clamp PJ/CL/L) on underside
Location bushes
(Yellow dot)
-15-
Direction of
router travel
COMBI 1002
Strengthening the Joint
If the joint between the worktops is not
supported underneath, after some time the joint
may ‘sag’ and become misaligned; to reduce
this the joint should be reinforced with a loose
tongue or biscuit dowels. The biscuit jointing
cutter set Trend Ref. 342 can be used with a
portable router. The size of biscuit used should
be No. 20.
Underside View
Ref. BSC/20/100 (100 biscuits)
Ref. BSC/20/1000 (1000 biscuits)
A 650mm worktop should have at least 5
biscuits.
Sealing the Joint
Cutter Ref. 342
The cut edges of the joint should be coated with
a water-resistant adhesive, or sealant before
assembly, to prevent moisture seeping into the
core of the worktops, which would swell, and
disfigure the worktop.
Biscuit
-16-
No.20
Waterproof
PVA
SEALANT
Use a fine grit abrasive paper to clean up the
torn wood chips of both mating surfaces. Lightly
run the abrasive paper along the edges to de-nib
the cut chipboard edge. This will ensure a tidy
joint is achieved.
COMBI 1002
Routing the Corner Radius
Corner Radius
Special Note: Due to the nature of this
particular edge laminate, the corner radius will
be more awkward to laminate.
Location bushes
(Black dot)
Direction of
router travel
When cutting the radius hold the router guide
bush against the template radius. Feed left
to right.
It is recommended that
the router depth stops are
used and three or four
cuts are taken.
Quick action
clamp here
Cut with laminate
down
Cut with laminate
up
22.5° Mitre Joint
n For the left hand part of the 22.5 mitre joint
fit bushes into holes marked with a Blue
dot. The Blue dot will be uppermost.
Routing the Mitre Corner Joint
n Clamp jig using quick action clamps or
accessory clamps.
n When cutting keep guide bush against
edge of template. Feed left to right into the
postform edge.
Optional accessory
clamp PJ/CL/L on
underside
n For opposing joint keep bushes in the
same side.
n Repeat above operations for remainder
of joint.
Direction of
router travel
Postform edge
s
Po
Location bushes
(Blue dot)
tfo
rm
ge
ed
Cut with
laminate up
Postform edge
Cut with
laminate
down
Plan View of
Corner Joint
Cuts
Quick action
clamp here
Cut with
laminate
down
Postform edge
Optional accessory
clamp PJ/CL/S on
underside
Cut with
laminate up
-17-
Postform edge
Insert the three location bushes in holes
marked Black dot as shown opposite.
Locate the template on the worktop as
illustrated ensuring the location bushes are
touching the worktop edge. Clamp into
position with quick action clamps.
COMBI 1002
Routing the Curved Peninsular
Curved Peninsular
Insert the three location bushes in holes
marked White dot as shown below.
Location bushes (White dot)
Locate the template on the worktop as
illustrated ensuring that location bushes
are touching the worktop edge. Clamp into
position with quick action clamps.
It is recommended that depth stops are used
and at least three or four cuts taken. White
discs must be uppermost when routing.
Quick action
clamp here
Postform edge
When cutting the curved peninsular, hold the
router guide bush against the edge of the
template. Cut from left to right.
Direction of
router travel
Postform edge
Peninsular End Cuts
Cut with
laminate
down
Peninsular
Postform edge
In order to prevent break out
of the laminate, rotation of the
cutter and feed direction of the
router must always be into the
postform edge of worktop.
Postform edge
Postform edge
Cut with
laminate
up
-18-
COMBI 1002
45° End Cut
Routing the 45° End Cut
Insert the three location bushes into holes
marked Grey dot as shown below.
Locate the template on the worktop as
illustrated ensuring that bushes are touching
the worktop edge. Clamp using two quick
action clamps.
Location bushes
(Grey dot)
It is recommended that depth stops are used
and three or four cuts taken. Cut from left
to right. Grey dot must be uppermost when
routing.
Peninsular End Cuts
Postform edge
Quick action
clamp here
Cut with
laminate
down
In order to prevent break out
of the laminate, rotation of the
cutter and feed direction of the
router must always be into the
postform edge of worktop.
Postform edge
Peninsular
Postform edge
Postform edge
Postform
edge
Direction of
router travel
Cut with
laminate
up
-19-
COMBI 1002
Cable Tidy Inserts & 35mm Circular
Hinge
The cable tidy Insert template is for use with
three sizes of plastic inserts, 60mm diameter
and 80mm diameter round inserts and a
105mm x 55mm rectangle insert.
For mixer tap
Mixer
tap
For 60mmØ insert
For 35mm kitchen door hinge
For 105mm x 55mm rectangle insert
For 80mm insert
Cable Tidy Inserts
35mm Circular Hinge
n Ensure machine is isolated from power supply
before making any adjustments.
n The template can also be used to rout 35mm
diameter blind holes for 35mm circular
concealed hinges for kitchen and cabinet
doors.
n Fit a 30mm template guide bush onto the
router base. Fit a 12.7mm (1/2”) diameter
straight router cutter into the collet assembly.
n Set-up procedure is the same as plastic
inserts, except the final depth of cut is 11mm,
and the centre of the blind hole must be
routed flat.
n Set depth of cut on router, maximum cut in
one pass should be about 8mm.
Accessory Cable Tidy Insert Chart
n Position template onto the required position
on the workpiece. Using two clamps securely
clamp the template to the workpiece ensuring
the clamps will not foul the path of the router.
Insert
72
n Place guide bush into required hole in
template, switch on router and plunge cut into
the workpiece, rout in a clockwise direction.
Repeat operation at progressive depths until
hole is cut. Due to build-up of wood waste it is
advisable to clean out the routed trench every
so often.
n Once the hole is routed, unclamp the template
and fit the plastic insert.
-20-
22
60
3
92
22
80
118
55
3
68
105
Colour
Ref.
(3 pack)
light grey
brown
black
CTI/60/PK1
CTI/60/PK2
CTI/60/PK3
light grey
black
CTI/80/PK1
CTI/80/PK3
grey
brown
black
CTI/105/PK1
CTI/105/PK2
CTI/105/PK3
Application
COMBI 1002
Routing 3/4” BSP Hole
Cutter/Guide Bush Concentricity
Checker
n Isolate power to the router.
n Place jig on a support with the cutter/guide
bush concentricity checker counterbore side
uppermost.
Please check hole size is suitable for
mixer tap.
n Place the router with 30mm guide bush and
12.7mm diameter router cutter fitted, into the
counterbored hole.
n Place jig in position so that hole in jig is over
hole position.
n Mark position of hole for tap in worktop.
n Secure the depth of cut for 8-10m and plunge
cut. Repeat at different depths until hole is
routed.
n Slowly plunge the router down until the cutter
enters the smaller hole, if the cutter does not
enter the hole it is not concentric to the guide
bush.
After use, store jig carefully.
n If the cutter is not concentric either re-set Ref.
UNIBASE if fitted (as it may have moved) or
fit a Ref. UNIBASE to ensure guide bush and
cutter are concentric.
MAINTENANCE
Please use only Trend original spare parts and
accessories.
n If the guide bush is too loose in the 30mm
diameter recess the incorrect bush has been
fitted.
The jig has been designed to operate over
a long period of time with a minimum of
maintenance. Continual satisfactory operation
depends upon proper tool care and regular
cleaning.
n If the cutter is not a good fit to the 12.7mm
hole the cutter diameter may be incorrect.
Cleaning
n Regularly clean the jig with a soft cloth.
Routing Mixer Tap Hole
Lubrication
n Your jig requires no additional lubrication.
Please check hole sizes are suitable
for mixer tap.
Storage
n This jig should be stored in its packaging after
use, or it can be hung on wall brackets.
n An accessory carry case is also available.
Ref. CASE/1001.
n Ensure machine is isolated from power
supply before making any adjustments.
n Fit a 30mm template guide bush
into the router base. Fit a 12.7mm (1/2”)
diameter straight router cutter into the collet
assembly.
ENVIRONMENTAL PROTECTION
n Set depth of cut on router, maximum
cut in one pass should be about 8mm.
Recycle raw materials instead of disposing
as waste.
Packaging should be sorted for environmentalfriendly recycling.
The product and its accessories at the end of their
life should be sorted for environmental friendly
recycling.
n Position template onto the required
position on the workpiece. Using two
clamps securely clamp the template to the
workpiece ensuring the clamps will not foul
the path of the router.
n Place guide bush onto required hole in
template, switch on router and plunge
into the workpiece, rout in a clockwise
direction. Repeat operation at progressive
depths until hole is cut.
n Once the hole is routed, unclamp the
template and fit the mixer tap.
GUARANTEE
The jig carries a manufacturers guarantee in
accordance with the conditions on the enclosed
guarantee card.
-21-
COMBI 1002
Please use only Trend original spare parts.
COMBI 1002 - SPARE PARTS LIST
No.
Qty.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
3
1
0
0
0
0
1
1
1
0
0
0
1
v1.0 05/2003
Desc.
Ref.
Combi 1002 Jig
Alloy Bush
Length Setting Stop
Machine Screw Csk M8 x 50mm Slot
Washer 8.5mm x 32mm x 1.0mm
Knob M8
Combi Jig ‘O’ Ring Set for Bushes (Pack of 5)
Long Clamp
Short Clamp
Fixing Bolt Kit
Machine Screw Csk M8 x 35mm Slot
Washer
Wing Nut M8
Manual
COMBI/1002
CJ/BUSH
CJ/LSK
WP-SCW/41
WP-WASH/17
WP-KNOB/10
CJ/ORS
PJ/CL/L
PJ/CL/S
PJ/FBK
WP-SCW/40
WP-WASH/17
WP-NUT/13
MANU/1002
-22-
COMBI 1002
COMBI 1002 - SPARE PARTS DIAGRAM
v1.0 04/2003
1
2
2
14
7
3
4
8
5
9
10
11
12
13
-23-
6
COMBI 1002
TROUBLE SHOOTING
Fault
Cause
Remedy
n Joint does not fit correctly
at the radius.
Cutter or guide bush is the
incorrect diameter or location
bushes are not against
worktop edge.
Check concentricity of cutter
with guide bush. Cutter 12.7mm
diameter with 30mm diameter
guide bush. Ensure location
bushes touch worktop.
n The back edge of the joint
does not line up.
Either the length stop or
template was in the incorrect
position, or the worktop has
not pushed up against the
length stop when the joint
was cut.
Check position of length stop
and re-cut joints.
n When clamped together the
joint has irregular gaps.
The guide bush has drifted away
from the edge of the template
whilst cutting either part of the
joint, or wood chips in particle
board have torn slightly.
Check with a straight edge
which part of the joint is uneven
and re-cut (this can only be
done on the male cut) ensuring
that the guide bush is kept
against the template by
machining from left to right. Use
abrasive paper to remove torn
wood chips.
n Chipped laminate
Can be caused by a blunt cutter
or removing too much material
at one pass or exiting out of
postform edge.
Always use sharp cutters and
when cutting through the
laminate cut 3–4mm of material.
Maintain correct feed direction,
to ensure cutter enters
postform edge.
n Jig slipping on material
Clamps not secure or too deep
a cut being made or cutter is
blunt.
Check clamps for wear. Clamp
securely, take shallow passes,
use a sharp cutter.
n Cut joints not square
Router has tilted or operator
has leaned heavily on router
causing jig flex.
Ensure jig is supported and do
not push hard on router taking
shallow passes. Ensure weight
of router is on supported part
of jig and that the router is
upright.
n Assembled joint not flush
or bowed
Worktop different thickness or
worktop not flat (cupped).
Ensure worktop is same
thickness and flat.
-24-
MANU/1002 v5.0
RECYCLABLE
Trend Machinery & Cutting Tools Ltd.
Odhams Trading Estate St Albans Road
Watford WD24 7TR England
Tel: 0044(0)1923 249911
[email protected]
www.trend-uk.com
© Copyright Trend 2013. No part of this publication may be reproduced, stored or transmitted in any form without prior permission.
Our policy of continuous improvement means that specifications may change without notice. Trend Machinery and Cutting Tools
cannot be held liable for any material rendered unusable or any form of consequential loss. E&OE

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