TREND COMBI 66 User Manual

COMBI 66

-1-

Dear Customer

Thank you for purchasing this Trend product, we
hope you enjoy many years of creative and
productive use.

Please remember to return your guarantee card
within 28 days of purchase.

TECHNICAL DATA

Jig thickness 16mm
Cutter size 12.7mm
Workpiece thickness max. 45mm
Worktop width: min. 580mm

max. 650mm
Guide bush size 30mm
Weight 3.3kg

CONTENTS

TECHNICAL DATA _____________________1

SAFETY ____________________________2-3

ITEMS ENCLOSED ____________________4

DESCRIPTION OF PARTS _______________5

ACCESSORIES

– Recommended Cutters ________________6

– Sub-base Sets & 30mm Guide Bush ____6-7

– Panel Connector Bolts _________________8

– Biscuit Jointer for the Router & Clamp ____8

– Carry Case __________________________9

ASSEMBLY

– Location Bush Identification ____________10

– Margin Distance _____________________10

– Setting out the Joints _________________10

OPERATION

– Setting the Length Stop _______________ 9

– Female Joint_________________________9

– Male Joint__________________________10

– Out-of-Square Joints _________________10

– Cutting the Bolt Recesses _____________11

– Strengthening the Joint _______________12

– Sealing the Joint ____________________12

– Curved Peninsular ___________________15

MAINTENANCE ______________________15

ENVIRONMENTAL PROTECTION
& GUARANTEE ______________________15

SPARE PARTS

– Spare Parts List _____________________16

– Spare Parts Diagram _________________16

TROUBLE SHOOTING _________________IB

☎

If you require further safety advice,
technical information or spare parts,
please call our technical support
department on 01923 224681.

The following symbols are used throughout this
manual:

Denotes risk of personal injury, loss of
life or damage to the tool in case of non­observance of the instructions in this
manual.

Refer to the instruction manual of
your power tool.

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
98/37/EC (identified by the CE marking on the
power tool).

INTENDED USE

This jig is intended for use with a plunge router
with suitbale guide bush and router cutter fitted
to rout a kitchen joint in laminate covered
particle board.

MANU-COM66 v2.0 24/10/05 3:30 pm Page 1

COMBI 66

-2-

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.

Users should also read the HSE/HSC
Safe Use of Woodworking Machinery
Approved Code of Practice and Guidance
Document and any amendments.

Users must be competent before using
our products.

IMPORTANT NOTE:

Residual Risk. Although the safety
instructions and operating manuals for
our tools contain extensive instructions on
safe working with power tools, every
power tool involves a certain residual risk
which cannot be completely excluded by
safety mechanisms. Power tools must
therefore always be operated with
caution!

General

1. Disconnect power tool when making

any adjustments. When not in use,
before servicing and when changing
accessories such as cutters,
disconnect power tool and attachment
from power supply. Ensure the
machine is switched off before
plugging tool in or connecting to a
power supply.

2. Always mount the power tool,

accessory or attachment in conformity
with the present instructions. The tool
should not be modified or used for any
application other than that for which it
was designed.

3. Keep children and visitors away. Do

not let children or visitors touch the
tool, accessory or attachment. Keep
children and visitors away from work
area. Make the workshop child proof
with padlock and master switch.

4. Dress properly. Do not wear loose

clothing or jewellry, they can be
caught in moving parts. Rubber
gloves and non-skid footwear is
recommended when working
outdoors. Wear protective hair
covering to contain long hair.

5. Consider working environment. Do

not use the product in the rain or in a
damp environment. Keep work area
well lit. Do not use power tools near
gasoline or flammable liquids. Keep
workshop at a comfortable
temperature so your hands are not
cold. Connect machines that are used
in the open via a residual current
device (RCD) with an actuation
current of 30 mA maximum. Use only
extension cables that are approved for
outdoor use.

6. The accessory or attachment must 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. Use the attachment with the power

tools and accessories specified in this
manual only. Do not force the tool or
attachment to do a job for which it is
not designed.

9. Secure idle tools. When not in use,

tools should be stored in a dry and
high or locked up place, out of reach
of children.

10. For best control and safety use both

hands on the power tool and
attachment. Keep both hands away
from cutting area. Always wait for the
spindle and cutter to stop rotating
before making any adjustments.

11. Always keep guards in place and in

good working order.

12. Remove any nails, staples and other

metal parts from the workpiece.

13. Maintain tools and cutters with care.

Keep cutters sharp and clean for
better and safer performance. Do not
use damaged cutters. Follow
instructions for lubricating and
changing accessories. Keep handles
dry, clean and free from oil and
grease.

14. Maintain accessories. Do not use

damaged accessories. Only use
accessories recommended by the
manufacturer.

15. Check damaged parts. Before

operation inspect the attachment, the
power tool, the cable, extension cable
and the plug carefully for signs of
damage. Check for alignment of
moving parts, binding, breakage,
mounting and any other conditions
that may effect its operation. Have
any damage repaired by an
Authorised Service Agent before using
the tool or accessory. Protect tools
from impact and shock.

16. Do not use tool if switch does not turn

it on or off. Have defective switches
replaced by an Authorised Service
Agent.

17. Don't over reach. Keep proper

footing and balance at all times. Do
not use awkward or uncomfortable
hand positions.

18. Don’t abuse the cable. Never carry

power tool or accessory by cord or
pull it to disconnect from the socket.
Keep cord from heat, oil and sharp
edges. Always trail the power cord
away from the work area.

19. Connect dust extraction equipment.

If devices are provided for the
connection of dust extraction and
collection facilities, ensure these are
connected and properly used.

20. Check all fixing and fastening nuts,

bolts and screws on power tool,
attachment and cutting tools before
use to ensure they are tight and
secure. Periodically check when
machining over long periods.

21. 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.

22. Personal Protective Equipment

(PPE). All PPE must meet current
UK and EU legislation.

23. Do not leave tools running

unattended. Do not leave tool until it
comes to a complete stop.

24. Always clamp workpiece being

machined securely.

25. Only use cutting tools for

woodworking that meet EN847-1/2
safety standards, and any
subsequent amendments.

26. 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. Disconnect router power tool. When

not in use, before servicing and when
changing accessories such as
cutters, disconnect router and
attachment from power supply.

2. Ensure router cutter has stopped

rotating before changing it. Never
use the spindle lock as a brake.

3. Remove adjusting keys and

spanners. Form the habit of checking
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.

MANU-COM66 v2.0 24/10/05 3:30 pm Page 2

COMBI 66

-3-

5. Eye protection. Wear safety goggles,

spectacles or visors to protect the
eyes from ejected waster particles.

6. Respiratory protection. Wear a face

or dust mask, or powered respirator.
Dust masks/filters should be changed
regularly.

7. Do not switch router on with the cutter

touching the workpiece.

8. The direction of routing must always

be opposite to the cutter's direction of
rotation. Do not back-cut or climb-cut.

9. At the end of the cut, release the

router plunge and allow spindle to
stop rotating before putting machine
down.

10. Check before cutting that there are no

obstructions in the path of the router.
When cutting through the full
thickness of the workpiece, ensure
there are no obstacles beneath
workpiece, and that a sacrificial work
surface is used.

Router Cutter Safety

1. Cutting tools are sharp. Care should

be taken when handling them.

2. Always use cutters with a shank

diameter corresponding to the size of
the collet installed in your tool.

3. Always run router cutters at the

spindle speed recommended and
marked accordingly. Ensure cutter
has reached correct speed before
entering workpiece. Recommended
speeds can be found on the
packaging, in cutter instructions, in the
Trend Routing Catalogue or on our
website.

4. Always use router cutters in a router.

Router cutters must not be used in a
drill. Drill and boring bits must not be
used in a router. Router cutters must
only be used for the material cutting
application for which they are
designed. Do not use on metal or
masonry.

5. Never use cutters with a diameter

exceeding the maximum diameter
indicated in the technical data of the
powertool or attachment used.

6. Do not drop cutters or knock them

against hard objects. Do not use
cutters that are damaged.

7. Cutters should be kept clean. Resin

build up should be removed at regular
intervals with Resin Cleaner

®

. The

use of a dry lubricant (Trendicote

®

PTFE) will act as a preventative. Do
not use PTFE spray on plastic parts.

8. When using stacked tooling (multi-

blade, block and groover etc.) on a
spindle arbor, ensure that the cutting
edges are staggered to each other to
reduce the cutting impact.

9. Cutter shanks should be inserted into

the collet to the line indicated on the
shank. This ensures that at least

3

⁄

4

of the shank length is held in the
collet. Do not over-tighten the collet
nut as this will score the shank and
create a weakness and fracture point.

10. Observe the correct assembly

instructions in the router instruction
manual for fitting the collet and nut.
Observe the router power tool manual
instructions on fitting cutters correctly.

11. It is advisable to periodically check

the collet and collet nut. A worn,
distorted or damaged collet can cause
vibration and damage the shank, and
should be replaced. Worn collet nuts
should be replaced.

12. Do not take deep cuts in one pass;

take several shallow or light passes to
reduce the side load applied to the
cutter. Too deep a cut in one pass can
stall the router.

13. Very small diameter cutters must be

handled and used with care.

14. Always return cutter to its packaging

after use.

15. Should you experience excessive

vibration during use stop immediately.
Have the eccentricity of the router,
router cutter and clamping system
checked by a qualified repair agent.

16. All fastening screws and nuts should

be tightened using the appropriate
spanner or key in accordance with the
manufacturers instructions.

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.

3. Always use a push-stick or push-block

when making any cut less than
300mm in length or when feeding the
last 300mm of the cut.

4. The opening around the cutter should

be reduced to a minimum using
suitably sized insert rings in the table
and closing the back fence cheeks or
fitting a false fence on the back fence.

5. Whenever possible use a work

holding device or jig to secure
component being machined.

6. Ensure attachment is securely fitted to

the workbench, with table surface at
approximately hip height.

7. Ensure a No-Volt Release Switch is

fixed to or adjacent to the attachment,
is easily accessible and that it is used
correctly.

8. 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).

9. In overhead mode, stand to the front

left of the machine table and the feed
direction is from the left.

10. 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.

11. 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. Take many light passes rather than

one deep cut to reduce the side load
applied to both router and router
cutter.

3. Trial cuts should be made on waste

material before starting any project.

4. When using some attachments

including a router table or dovetail jig,
the use of a fine height adjuster is
highly recommended.

5. 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 Maintenance

1. Composite cutting tools (brazed tip)

must be maintained 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.

2. The design of composite tools must

not be changed in the process of
maintenance. When re-grinding the
tool, care must be taken not to cause
weakening of the body or the
connection between the cutting edge
and the body.

3. Replacement parts must meet Trend

specification.

4. Tolerances which ensure correct

clamping by the collet shall be
maintained.

Version 6.0 05/2005

MANU-COM66 v2.0 24/10/05 3:30 pm Page 3

COMBI 66

-4-

ITEMS
ENCLOSED

COMBI JIGJIG

C

O

M

B

I

J

I

G

JIG

GUARANTEE

x1

x3

x1

x1

x1

x1

x1

x1

ITEMS REQUIRED

■ 1/2” plunge router.

■ 30mm guide bush.

■ 12.7 diameter x 50mm cut router cutter with

1/2” shank.

■ Trestle x 2.

■ 100mm throat clamp x 2.

■ Hand tools.

■ Panel connector bolts.

■ Wooden biscuits size No.20.

■ Sealant.

MANU-COM66 v2.0 24/10/05 3:30 pm Page 4

COMBI 66

-5-

DESCRIPTION
OF PARTS

COMBI JIGJIG

AE

D

G

G

K

DDCHF

IF

JBG&I

L

M

N

O

Jig body

Label

Postform joint slot

Female joint bush location hole

Length setting stop location hole

Male joint bush location hole

Peninsular joint bush location hole

Length stop fixing holes

Bolt recess bush location hole

Connecting bolt recess slot

Alloy location bush

Length setting stop

Length setting stop bolt

Length setting stop washer

Length setting stop knob

N

O

M

L

K

J

I

H

G

F

E

D

C

B

A

MANU-COM66 v2.0 24/10/05 3:30 pm Page 5

COMBI 66

-6-

Sub-base Sets

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.

ACCESSORIES

Description Order Ref.
RT/13 Spare blades RB/H (1 off)

RB/H/10 (10 off)

Description Order Ref.
RT/11 Spare blades RB/A (1 off)

RB/A/10 (10 off)

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

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

Description Order Ref.
Universal sub-base UNIBASE

Ref. RT/13X1/2TC

Ref. RT/11X1/2TC

Ref. UNIBASE

MANU-COM66 v2.0 24/10/05 3:30 pm Page 6

COMBI 66

-7-

Fits following Router Models

Description Order Ref.

Elu MOF31,77,98,131,177(E),
Bosch GOF1600A & 1700ACE
DeWalt DW625EK, 629
Performance Pro CLM2050R,
CLM1250R >11/2003
Felisatti R346EC, TTECH TTR127

GB/5

Makita 3612BR & 3600B
Ryobi RE600N & R600N, RE601

GB/5/A

Hitachi M12V, M12SA & TR12

GB/5/D

Makita 3612C & 3612

GB/5/J

Flex OFT3121VV, 2926W
Portercable 7539, 7519, 7529, 97529

GB/5/M

Performance Pro CLM1250R <11/2003

GB/5/P

Triton TRB001

GB/5/Q

Felisatti TP246(E)
Festo OF2000E, Mafell L065E,
Metabo OF1612 & OFE1812,
Ryobi R500 & R502, Skil 1875U1,
Wadkin R500 & Nutool XP12

GB/5/S*

*Please state model when ordering.

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

Ref. GB/5

Description Order Ref.
30mm guide bush to fit sub-base GB30

MANU-COM66 v2.0 24/10/05 3:30 pm Page 7

COMBI 66

-8-

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.

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.

Clamps

Ref. FC/200

Two heavy duty quick action or gripper clamps
are required to secure the jig to the worktop.

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.

100mm (4”) min.
throat depth

MANU-COM66 v2.0 24/10/05 3:30 pm Page 8

No.20

COMBI 66

-9-

6

Carry Case

Hard wearing carry case to protect and allow
ease of carrying of the COMBI66 Jig.

Description Order Ref.
Carry Case for COMBI66 CASE/66

MANU-COM66 v2.0 24/10/05 3:30 pm Page 9

COMBI 66

-10-

ASSEMBLY

Location Bush Identification

Three location bushes are used in different holes
in the jig to align the correct template aperture
for the application.

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.

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.

23mm

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.

COMBI JIG

Margin Distance

Allow 8.5mm when cutting joints. Measure or
use a batten of this thickness to aid setting out.

Plan view
of joints

Peninsular holes

Length stop

setting holes

Peninsular hole

Female holes

O ring

Location bush

Cutter

Sub base

Guide bush

30mm Ø

Location
bush

Worktop

Template

8.5mm

Right hand joint

Male

Female

Male

Female

Cut male with laminate down

Cut female with laminate up

Postform edge

The joint takes up 23mm, this should
be allowed for with extra material in the
length of the male worktop.

Male

Female

Postform edge

PENINSULAR

Postform edge

Postform edge

Male

Female

Left hand joint

Cut male with laminate up

Cut female with laminate down

Bolt recess holes

Male holes

MANU-COM66 v2.0 24/10/05 3:30 pm Page 10

COMBI 66

-11-

Routing the female part of the Joint

COMBI JIG

Location bushes

in female hole

Quick action

clamp here

Length

stop bush

Router feed

direction

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.

Postform

edge

The edge of the jig slot that is not used is
notched to act as a visual guide.

Length Stop Arrangement

OPERATION

Setting the Length Stop for the
Female Joint

Carry out the setting operation first:

■ Fit bushes into length stop setting holes
and offer the jig to the male worktop as
shown. The label will be uppermost.

■ Position the jig across the width of the
male worktop. Loosely fit the length stop.

■ Fasten length stop to template so that it
traps the template across the worktop
between the male location bushes and the
stop. Tighten up the knob.

■ Remove the bushes from male location
hole. The template is now set to cut the
correct length of joint for the female cut.

Female Joint

■ Fit two location bushes in female holes as
shown. (The label must be uppermost.)
Leave the length stop bush in position.

■ Place the template onto the female
worktop to be cut, ensuring the location
bushes are touching the worktop. Now
cramp securely in position using two quick
action clamps ensuring they will not foul
the router path.

■ Set cutter depth.

■ Plunge router and cut joint in a series of

passes, feeding left to right. At the end of
the cut release plunge.

COMBI JIG

Setting the Length Stop

Location

bushes in length

stop setting holes

Postform edge

Length stop on

underside.
Retained with
screw & knob

Jig

Worktop

Length stop

Washer

Knob

Set the length stop using the worktop
width for te male cut, as this may be
different to the female worktop width.

MANU-COM66 v2.0 24/10/05 3:30 pm Page 11

COMBI 66

-12--12-

Male Joint

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 from
underside. 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
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.

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.

■ Insert two location bushes into male holes as
shown, label facing down.

■ Place template across the width of the
worktop and clamp securely to worktop.

■ Set cutter depth. Plunge router and cut the
male joint before finally cutting the work-top to
length. A series of passes should be made
feeding from left to right. At the end of the cut
release plunge.

Out-of-square Joints (max 3°)

Only the male cut needs to be adjusted if an out­of-square joint is required. On out-of-square
joints there is a possibility of the chipboard core
of the worktop becoming exposed which will
need to be hidden with sealant.

Depending on accessibility mark out an out-of­square joint, first lay the female board on the
cupboard carcass in position. Next lay the male
section of board on to the carcass and on top of
the female section of the board. Support other
end. Mark around the female joint onto the male
section of board.
If inaccessible lay female onto male.

■ Use only the one location bush in the male
hole indicated.

■ Swing the template to suit the angle required
and clamp down.

■ Remember to allow an 8.5mm gap between
template and cutting line.

Routing the male part of the Joint

Quick action

clamp here

Direction of

router travel

Location bush in

male hole

Cutting out-of-square male joint

Quick action

clamp here

Use only one male

location hole

Direction of
router travel

Postform edge

Postform edge

Shown
exaggerated

Test fit the joints together,
abrasive paper may be required
to clean up the chipboard core.

MANU-COM66 v2.0 24/10/05 3:30 pm Page 12

COMBI 66

-13-

COMBI JIG

Cutting the Bolt Recesses

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. The bolt recess position can
be gauged approximately 150mm from the
edge of the postform edge, or where access
is possible with kitchen units. Mark with
pencil both positions on the underside of the
worktop.

Insert the location bushes into the bolt recess
holes as shown.

■ The template may need to be inverted
when cutting some bolt recesses.

■ Securely clamp jig to worktop.

■ The bolt recesses should be

approximately 22mm deep although
this will depend upon the thickness
of worktop.

■ Once one bolt recess is cut move jig
over to the remaining pencil lines and
repeat.

■ Repeat the procedure for the male joint.

Routing the bolt recess in the
female part of the joint

COMBI JIG

Quick action

clamp here

Quick action

clamp here

150mm

Location bushes in

bolt recess hole

Pencil mark

Direction of

router travel

Worktop Depth

Thickness Recess

30 22mm
40 28mm

Routing the bolt recess in the
male part of the joint

150mm

Location bushes in

bolt recess hole

Pencil mark

Direction of

router travel

Quick action

clamp here

Underside of

worktop

Postform edge

Underside of worktop

Best results are achieved when the
centre line of the bolt corresponds
to the centre line of the worktop.
Clamp jig securely to worktop.

MANU-COM66 v2.0 24/10/05 3:30 pm Page 13

COMBI 66

-14-

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, C152 or TR35 can be
used with a portable router. The size of biscuit
used should be No. 20.

Ref. BSC/20/100 (100 biscuits)
Ref. BSC/20/1000 (1000 biscuits)

A 650mm worktop should have at least 5
biscuits.

Sealing the Joint

The cut edges of the joint should be coated with
a water-resistant adhesive, or Trend Fill & Seal

®

sealant before assembly, to prevent moisture
seeping into the core of the worktops, which
would swell, and disfigure the worktop

Cutter Ref. 342 shown

No.20

PVA

SEALANT

Waterproof

Biscuit

Underside View

MANU-COM66 v2.0 24/10/05 3:30 pm Page 14

COMBI 66

-15-

Curved Peninsular

Insert the three location bushes in the holes
as shown.

Locate the template on the worktop as
illustrated ensuring that location bushes are
touching the worktop edge. Clamp into
position with quick action clamps.

When cutting the curved peninsular, hold the
router guide bush against the edge of the
template. Cut from left to right.

It is recommended that depth stops are used
and at least three or four cuts taken.

Quick action

clamp here

Postform edge

Location bushes

Direction of
router travel

Cut with

laminate

down

Cut with
laminate

up

Postform edge

Postform edge

Postform edge

Postform edge

Peninsular

Peninsular End Cuts

Routing the Curved Peninsular

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.

MAINTENANCE

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.

Cleaning

■ Regularly clean the jig with a soft cloth.

Lubrication

■ Your jig requires no additional lubrication.

ENVIRONMENTAL PROTECTION

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.

GUARANTEE

The jig carries a manufacturers guarantee in
accordance with the conditions on the enclosed
guarantee card.

MANU-COM66 v2.0 24/10/05 3:30 pm Page 15

COMBI 66

-16-

COMBI 66 - SPARE PARTS DIAGRAM

1

2

4 5 6

8

7

3

COMBI JIG

COMBI 66 - SPARE PARTS LIST v1.0 04/2003

Item Qty Description Ref.

1 0 Combi 66 Jig COMBI/66
2 3 Alloy Bush CJ/BUSH
3 1 Length Setting Stop Kit CJ/LSK
4 0 Machine Screw Csk M8 x 50mm Slot WP-SCW/41
5 0 Washer 8.5mm x 32mm x 6.0mm WP-WASH/17
6 0 Knob M8 WP-KNOB/10
7 0 Combi Jig ‘O’ Ring Pack for Bushes (pack of 5) CJ/ORS
8 1 Manual MANU/66

v1.0 04/2003

1

2

7

3

8

4 5 6

MANU-COM66 v2.0 24/10/05 3:30 pm Page 16

COMBI 66

-IB-

Fault Cause Remedy

■ Joint does not fit correctly Cutter or guide bush is the Check concentricity of cutter
at the radius. incorrect diameter or location with guide bush. Cutter 12.7mm

bushes are not against diameter with 30mm diameter
worktop edge. guide bush. Ensure location

bushes touch worktop.

■ The back edge of the joint Either the length stop or Check position of length stop
does not line up. template was in the incorrect and re-cut joints.

position, or the worktop has
not pushed up against the
length stop when the joint
was cut.

■ When clamped together the The guide bush has drifted away Check with a straight edge
joint has irregular gaps. from the edge of the template which part of the joint is uneven

whilst cutting either part of the and re-cut (this can only be
joint, or wood chips in particle done on the male cut) ensuring
board have torn slightly. that the guide bush is kept

against the template by
machining from left to right. Use
abrasive paper to remove torn
wood chips.

■ Chipped laminate Can be caused by a blunt cutter Always use sharp cutters and

or removing too much material when cutting through the
at one pass or exiting out of laminate cut 3–4mm of material.
postform edge. Maintain correct feed direction,

to ensure cutter enters
postform edge.

■ Jig slipping on material Clamps not secure or too deep Check clamps for wear. Clamp

a cut being made or cutter is securely, take shallow passes,
blunt. use a sharp cutter.

■ Cut joints not square Router has tilted or operator Ensure jig is supported and do

has leaned heavily on router not push hard on router taking
causing jig flex. shallow passes. Ensure weight

of router is on supported part
of jig and that the router is
upright.

■ Assembled joint not flush Worktop different thickness or Ensure worktop is same
or bowed worktop not flat (cupped). thickness and flat.

TROUBLE SHOOTING

MANU-COM66 v2.0 24/10/05 3:30 pm Page 17

MANU/66 v3.0

© Copyright Trend 2005. 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

RECYCLABLE

Trend Machinery & Cutting Tools Ltd.

Odhams Trading Estate St Albans Road
Watford WD24 7TR England

Enquiries: __________________0800 487363
Technical Support:____0044 (0) 1923 224681
Fax: ________________0044 (0) 1923 236879
Email: [e-mail]
Web:____________www.trendmachinery.co.uk

MANU-COM66 v2.0 24/10/05 3:30 pm Page 18

COMBI 66

MANU-COM66 v2.0 27/10/05 10:56 am Page 19