TREND MINI ELLIPSE JIG Instructions Manual

MINI
ELLIPSE
JIG

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ME/JIG

INTRODUCTION

The Mini Ellipse Jig is ideal for routing elliptical
picture frames, mirrors, clocks and small coffee
tables.

The twin slider system produces perfect ellipses.

■ Axis points are fully adjustable

■ Single fixed slider can be locked to provide

circles up to 600mm diameter

■ Metric and imperial measurement scales for
accurate adjustment

■ Can be used as a drawing instrument by
fitting pen plug and plotter pen

■ Can be fitted to most makes of light duty
router, for which bolts are supplied

The following table shows limitations of sizes for
ellipses it is possible to make.

Major Axis Minor Axis

Max. Min.

580mm 520mm 430mm
500mm 450mm 360mm
400mm 340mm 250mm
300mm 250mm 160mm
220mm 160mm 160mm

IMPORTANT!
The Ellipse Jig should be used
and stored at normal room
temperature, and out of direct
sunlight to maintain a smooth
operation of the sliders.

1 x Main Plate

1 x Cross Frame

2 x Securing Knobs

2 x Index Washers

2 x Index Sleeves

2 x Ellipse Sliders

1 x Circle Slider

1 x Pencil Plug & Grommet

4 x Mounting Screws

ITEMS ENCLOSED

MINI
ELLIPSE
JIG

1 x Mounting Kit for router 1 x Manual

1 x Guarantee card

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ME/JIG

SAFETY P R ECAUT IO NS

■ Always switch off the power and unplug the

router when changing cutters or when making
adjustments.

■ Always wear protective goggles when routing.

■ Wear sound protective ear muffs when routing

for long periods of time.

■ Always wear a dust mask. Use dust extraction

equipment whenever possible.

■ Do not wear loose clothing. Make sure baggy

sleeves are rolled up and ties are removed.

■ Always remove spanners and hex keys from

the workpiece before switching router on.

■ Keep hands well clear of the router cutter

when routing.

■ Avoid accidental star ting of the router. Make

sure the power switch is in the ‘Off’ position
before plugging in and connecting to the
electrical supply.

■ Never leave the router unattended when

running. Always wait until the router comes to
a complete stop before making any
adjustments.

■ Do not switch the router on with the cutter

touching the workpiece.

■ Mount the material securely to a work bench.

■ Periodically check all nuts and bolts to make

sure they are tight and secure.

Cutter Care

■ Do not drop cutters or knock them against

hard objects.

■ Cutters should be kept clean. Resin build-up

should be removed at regular intervals with
Resin Cleaner

®

. The use of a dry lubricant

will act as a preventative such as Trendicote

®

PTFE spray.

■ Cutter shanks should be inserted into the

collet at least 3/4 of shank length to prevent
distortion. A distor ted collet should be
discarded, as it can cause vibration and

damage the shank.

■ Do not over-tighten collet as this will score the
shank and create a weakness there.

■ It is also advisable to periodically check the
router collet nut for wear.

Useful Advice

■ Judge your feed rate by the sound of the
motor. In time, the operator will acquire a ‘feel’
for the router, and a feed speed relative to the
work will come naturally. Too slow a feed will
result in burning.

■ Apply the normal precautions as with any
electric power tool.

■ The main abuse of routing machines is the
inclination for operators to overload them. The
motto is ‘Keep the revs up’. The drop in
revolutions should not exceed, if possible,
more than 20% of full running speed.

■ The motor of a router is susceptible to the
accumulation of sawdust and wood chips, and
should be blown out, or ‘vacuumed’,
frequently to prevent interference with normal
motor ventilation.

■ Refer to the Instruction Manual supplied with
your router for full details of it’s features and
safety information.

■ Trial cuts should be made on waste material
before starting any project.

■ Do not store the router on the floor, as
chippings, pins or dirt can drop into the air
intake of the router.

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ME/JIG

ASSEMBLY

Use the diagram below as a guide to assembling
the jig.

1

2

3

4

5

6

7

8

9

10

11

1. Main plate

2. Cross frame

3. Securing knob

4. Index washer

5. Index sleeve

6. Ellipse slider

7. Circle slider

8. Pen plug

9. Plotter pen

10. Mounting screws

11. Mounting kit for router

3

4

5

10

10

10

6

11

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ME/JIG

Mounting Router

Bolts are provided for mounting the router to the
router plate. See chart on page 6 for correct
selection. Ensure router spindle is central with
central hole in main plate. Slots are provided in
main plate to allow for the various positions of
the fixing points on the router base.

Certain router models will require additional nuts
and washers. The position of the router will vary
according to it's design. The removal of one of
the handles may be necessary with certain
models that require an 'in line' position.

IMPORTANT!
Please do not over-tighten
fixing bolts when fitting the
router to the router plate.

‘In Line' At 90°

Mounting Position of Routers

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ME/JIG

Screw sizes required for Mini Ellipse Jig

Make and model of Size and quantity Distance between Handle
suitable routers of mounting fixing centres position

machine screws of router

Trend T5 M5 x 20 (x2) 50mm At 90°
AEG OFE710, OF500S, OF450S M5 x 20 (x2) 50mm At 90°
Atlas Copco OFS50, OFSE850, OFSE1000, M5 x 20 (x2) 50mm At 90°

OFS720

Black & Decker BD66 M4 x 20 (x2) + Nut (x2) 48mm At 90°

+ Washers (4)
BD780(E), KW779, KW780(E)
KW800(E) M5 x 20 (x2) + Nut (x2) 50mm At 90°
SR100 M5 x 20 (x2) 50mm At 90°

Bosch POF400A M6 x 16 (x2) 75mm In Line

POF52 M6 x 16 (x2) 75mm In Line
POF500A, 600ACE M6 x 16 (x2) 75mm In Line
GOF900A, 900ACE, POF800ACE M4 x 20 (x2) + Nut (x2) 83mm At 40°

+ Washers (x2)

DeWalt DW613 M5 x 20 (x2) + Nut (x2) 50mm At 90°

DW620, 621 M4 x 20 (x2) 74mm At 60°

Einhell EOF850SP M5 x 20 (x2) 50mm At 90°
Elu MOF96(E) M5 x 20 (x2) 50mm At 90°

MOF69 M5 x 20 (x2) 50mm At 90°
OF97(E) M4 x 20 (x2) 74mm At 60°

Festo OF900(E), 650 M4 x 20 (x2) 65mm At 20°

1000(E)

Freud FT1000(E) M5 x 20 (x2) 74mm At 60°
Hitachi FM8 M5 x 20 (x2) 60mm At 90°

M8(V) M5 x 20 (x2) 60mm At 90°

Holzher 2335, 2336, 2356 M5 x 20 (x2) 50mm At 90°
Kango R855OS M5 x 20 (x2) 50mm At 90°
Kinzo 25C44 M6 x 16 (2) 72mm At 90°
Kress FM6955 M5 x 20 (x2) 50mm At 90°
Makita 3620 M5 x 20 (x2) 74mm At 90°
Mafell LO50E M5 x 20 (x2) 76mm At 22.5°
Metabo OF528, OF1028 M5 x 20 (x2) 65mm At 90°

OFE1229 M5 x 20 (x2) + Nut (2)

Nutool NPT850 M5 x 20 (x2) 50mm At 90°
Perles Eurotool OF808(E) M5 x 20 (x2) 50mm At 90°
Peugeot DEF570E, DF55E M6 x 16 (x2) 54mm In Line

M6 x 16 (x2) + Nut (x2)

Power Devil PDW5027 M5 x 20 (x2) 50mm At 90°
Ryobi R150, R151, RE155K, M5 x 20 (x2) 60mm At 90°

RE120 M6 x 16 (x2) + M6 Nut (x2) 54mm In Line

Skil* 1835U No.8 UNF x 3/4” (x3) Re-drill N/A

(not supplied)

Sparky X52E M5 x 20 (x2) 60mm At 90°
Stayer PR50 M5 x 20 (x2) 50mm At 90°
Virutex FR77C, 78C M5 x 20 (x2) 50mm At 90°

*The main plate will require drilling by the user when fitting the Skil router.

OPERATION
Basic Setting Up Procedure

for an Ellipse 480mm x 36 0mm

Marking out

■ Determine size of workpiece required.

■ Ensure chosen workpiece is sufficiently larger

to accommodate the ellipse and support the
jig.

■ Mark the centre lines for the major and minor
axis.

■ Mark overall dimensions of ellipse onto centre
lines.

Fixing Cross Frame

■ Position cross frame using the four sighting
marks on the perimeter of the cross frame.

■ Drill four 3.2mm (1/8”) diameter holes through
the holes of the cross frame into the
workpiece.

■ Using the four mounting screws, fix the cross
frame to the workpiece.

Setting Major Axis

■ Slide the two sliders into each slot at 90° to
each other.

■ Locate each of the pivot points over the
vertical pin of the slider.

■ Loosen both knobs, A and B.

■ Position the router over major axis mark, slide

main frame until cutter is positioned over
mark and check that index washer on pivot
point ‘A’ reads 240mm, then lock knob ‘A’.

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ME/JIG

Illustrations are symbolic and not to scale

A B

Major Axis

Major Axis

Minor Axis

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ME/JIG

Setting Minor Axis

■ Position router cutter over minor axis mark,
slide main frame until cutter is positioned over
mark and check that index washer on pivot
point ‘B’ reads 180mm, then lock knob ‘B’.

Setting up of the Mini Ellipse Jig is now
complete. Alternatively the positions of the pivot
points can be set before locating the pivot points
onto the slider pins using the measurement
scale. The calculation requires simply halving
the major and minor axis and allowing for the
cutter diameter.

Fixing Methods

The workpiece should be fixed onto a false or
waste piece to stop you damaging your work
bench.

There are many methods depending on the
application as follows:

1. 'G' clamps should be positioned outside the
swing area of the jig.

2. Camclamps are ideal as they will not
obstruct the jig. An adjustable camclamp jig
can be made for various sizes of ellipses.

3. Double-sided tape Ref. X/05/019 can be
used and rolled off easily after operation.

4. Spot gluing with a hot melt glue gun will
allow the workpiece to be prized off with
minimal surface damage.

5. Panel pins are a quick and easy method
providing the small holes are acceptable.

Choice of Material

Whilst it is perfectly possible to produce frames
with solid panels of natural wood, there will be a
weakness at the short-grained parts of the
ellipse. The frame will be delicate and liable to
break at these points unless care is taken. A
more professional approach is to use a series of
mitred jointed sections which overcome the
cross-grain problems and give an attractive
grained finish. Sections can be dowel or biscuit
jointed to give strength to the frame.

Routing Operation

■ Fit cutter, switch router on, plunge in and
make repeat sweeps with the router at 3mm
steps.

IM P O RTANT!
Note that when cutting or central
panelling, one can reverse direction
of feed to stop the electric cable
becoming twisted. However, when
edge moulding and cutting, feed
direction must be opposite to that
of the cutter.

IM P O RTANT!
Care should be taken on the last
cut prior to break through, as the
resultant ellipse or circular plaque
or ring can possibly move. Double­sided tape can be used to
eliminate any danger of this
occurring.

■ Tr ial runs should be made on scrap material
when first using this Jig.

Minor Axis

B

A

Weakest points & possible

poor/rough finish

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ME/JIG

Wastepiece

Workpiece

Ellipse

Jig

Frame

Table

Frame

Guide rods

Workboard

Ski

Frame

Guide rods

Template

Workboard

Ski

Guide bush

For batch production of
elliptical frames, the
ellipse jig is used to cut
an elliptical template from
thin plastic or hardboard.

The template is
then used to cut

and profile the
frames in the
conventional

manner.

Cutters suitable for Elliptical
Routing

Straight Flute Cutter

Trend Ref. 3/20 or 3/20L.
To cut an elliptical or
circular shape, use a
narrow two flute straight
cutter which is long enough
to break-through the
material.

Ogee Cutter

Trend Ref. 46/230.
This type of bearing guided cutter
is ideal for moulding the frame or
plaque once it has been cut out
using the ellipse jig. Best used
with the router in a table.

Panelling Cutter

Trend Ref. 18/52.
Can be used with an
elliptical template made on
the ellipse jig in conjunction
with a guide bush fitted to
the router.

Rebate Cutter

Trend Ref. 46/39.
Used to create the
recess for the backing
piece and glass. The
cutter is supplied with
four bearings to allow
alternate widths of
rebate.
Rebate widths =
8mm, 9.5mm, 11mm
and 12.7mm.

Suggested methods of working

Using Ellipse Jig

Cuts should be
made at repeated
depths of 2-3mm,
depending on the
material.

Using Router Table

A lead on piece should be used when
performing any bearing guided work.

A support pad
can be made to
prevent the
router from
tipping over
when routing the
frame.

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ME/JIG

Remove frame from workboard and lightly sand
to remove any imperfections that may affect the
following stages.

Producing a Natural Timber
Frame

Draw frame onto workboard by fitting plotter pen
attachment to the ellipse jig.

Plan the wood sections to fit the frame allowing
enough waste material to support the jig.
Calculate the angles and lengths of the sections
and cut accurately.

Glue wood sections together to form the frame.
Dowel joints can be used for extra strength.

Secure frame to workboard by using double­sided tape or spot hot melt gluing. Fit a scrap
piece (the same thickness as the sections) to the
centre in the same way.

Drill and screw cross frame to the centre of the
scrap material.

Rout the outside edge of the frame in an anti­clockwise direction at repeated depths of 2-3mm
until breakthrough is achieved.

Rout the inside edge of the frame in a clockwise
direction at repeated depths of 2-3mm until
breakthrough is achieved.

1.

2.

3.

4.

5.

6.

7.

8.

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ME/JIG

Picture

Hardwood

Glass

Routing the rebate on a router
table

Using Trend Ref. 46/39.
The rebate for the glass and
backing piece can be produced
with a bearing guided rebate
cutter inverted in a table as
shown.
Alternatively, the frame can be
left fitted to the work-board as in
step 8 and the ellipse jig
adjusted so that the correct sized
rebate can be made with the
same two flute cutter as used to
cut the frame.

Routing the outside mould on
a router table

Using Trend Ref. 46/230.
The moulding of the frame is
best suited to a table mounted
router fitted with a bearing
guided cutter. The frame is
inverted with the face side down
onto the table. The cutter should
be well guarded and the frame
rotated against the rotation
direction of the cutter.
Two passes at increased depths
may be necessary to cut the
mould safely.

Routing the inside mould on a
router table

Using Trend Ref. 46/41.
Repeat the above procedure to
rout the outside mould.

When routing out the backing hardboard piece,
secure the cross frame with double-sided tape.

Glass

Picture

Hardwood

9. plan

10. plan

11. plan

12.

Faceside

Underside

Rotate frame

clockwise

Lead-on
piece

Rotate frame

anti-clockwise

Rotate frame

clockwise

Lead-on
piece

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ME/JIG

Producing an Elliptical Plaque in MDF

This example does not include the use of bearing guided cutters

moulded plaque

waste piece

Draw plaque dimensions onto workpiece and
clamp to a false baseboard to prevent routing
into the workbench. Secure centre area of
plaque to baseboard (see clamping section) to
prevent plaque from moving when breakthrough
is achieved.

Align the cross frame with the line up notches. It
is advisable to secure the cross frame to the
workpiece using double-sided tape, this is easily
removable and will not damage the workpiece.

Produce the mould required with a panel type
cutter.

Repeated operations can be
made with more cutters to
achieve a custom design of
mould. Adjustment in the size
of the ellipse can be made by
using the measurement scale
on the main plate to adjust both
pivot point positions.

Change the cutter to a straight and take
repeated passes until breakthrough is achieved.

1.

2.

3.

4.

Guarantee

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

Recycling

■ Jig, accessories and packaging should be
sorted for environmentally friendly recycling.

ME/JIG

-IB-

ME/JIG - SPARE PARTS LIST v3.0 01/2000

MINI
ELLIPSE
JIG

13

12

4

Item Qty Description Ref.

1 1 Main Plate WP-MEJ/1
2 1 Cross Frame WP-MEJ/2
3 1 Plate Support c/w Pins WP-MEJ/3
4 2 Index Washer WP-MEJ/4
5 2 Index Sleeve WP-MEJ/5
6 2 Ellipse Slider WP-MEJ/6
7 1 Circle Slider WP-MEJ/7

8 1 Pencil Plug and Grommet WP-MEJ/8
10 4 Screw Wood No 8 x 25mm WP-SCW/100
11 1 Mounting Kit For Router WP-MEJ/11
12 2 Knob Female M10 WP-MEJ/12
13 1 Manual MANU/MEJ

12

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5

5

10

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10

10

6

2

6

7

8

3

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1