Combi 650
-2-
ITEMS ENCLOSED
Length = 760mm
Width = 360mm
Thickness = 13mm
Weight = 4.2kg
Specification
1 x Solid laminate template
2 x Location bushes
1 x Manual
1 x Guarantee card
1 x Length setting stop
1 x Machine screw csk
1 x Washer
1 x Knob
Combi 650
-3-
SAFETY P RECAUT I O N S
■ 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 or respirator. 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 starting 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 workpiece securely to a work
bench or to a workboard fitted to a suitable
surface.
■ 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 distorted 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 its features and
safety information.
■ Trial cuts should be made on waste material
before starting any project.
Combi 650
-4-
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.
Description Order Ref.
Craft Range Cutter C153x1/2TC
As above with TC centre tip C153Dx1/2TC
Trade Range Cutter TR17x1/2TC
As above with TC centre tip TR17Dx1/2TC
Professional Range Cutter 3/83x1/2TC
As above with TC centre tip 3/83Dx1/2TC
As per 3/83 but with shorter shank
for Makita, Ryobi & Hitachi routers 3/83Mx1/2TC
Replaceable tip cutter RT/11x1/2TC*
Above cutter (with shorter shank)
for Makita, Ryobi & Hitachi routers RT/11Mx1/2TC*
Replacement blade (1 off) RB/A
Replacement blade (10 off) RB/A/10
*This cutter has a 30mm tip length but will cut to a
maximum depth of 50mm.
Order Ref. C153, TR17D, TR17, 3/83D, 3/83M
Order Ref. RT/11, RT/11M
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
two line-up pins. The line-up pins and bush
ensure exact alignment of sub-base with router
spindle, when fitted with the relevant collet.
r o u t i n g t e c h n o l o g y
R
trendtrend
GB/5 SUB-BASE
Fits following Router Models
Description Order Ref.
Elu MOF31,77,98,131,177(E),
Bosch GOF1600A & 1700ACE
DeWalt DW625EK
Felisatti R346EC
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
Bosch 1300ACE
GB/5/K
Freud FT2000E
AEG OFSE2000
Casals FT2000VCE
GB/5/L
Flex OFT3121VV,
Portercable 7539, 7519
GB/5/M
Felisatti TP246(E), Festo OF2000E,
Kinzo 25C46, Mafell L065E,
Metabo OF1612 & OFE1812,
Performance PRO1250,
Ryobi R500 & R502, Skil 1875U1,
Triton TRB001, Wadkin R500
GB/5/S*
*Please state model when ordering.
GB/5 Set comprises the following
Sub-base
GB10
170mm Ø x 8mm
1
/2” shank
line-up pin
1
/4” shank
line-up pin
t
r
e
n
d
1
0
m
m
R
ACCESSORIES
Combi 650
-5-
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. Per iodically check the sub-base is concentric
to the spindle of the router.
UNIBASE comprises the following
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)
Faithful FPPR2000E
Felisatti TP246(E), R346EC
Festo OF2000E
Freud FT2000E
Hitachi MI12V, M12SA, TR12
Metabo OF1612, OFE1812
Ryobi RE600N, R600N, RE601, R500, R502
Skil 1875U1
Wadkin R500
Description Order Ref.
Universal sub-base UNIBASE
t
r
e
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3
0
m
m
R
GB30 30mm Guide Bush
Description Order Ref.
30mm guide bush to fit sub-bases GB30
UNIBASE
UNIBASE
170mm Ø
x 8mm
1
/4”+ 1/2”
shank
line-up pin
8mm +
12mm shank
line-up pin
1/2"
12mm
1/4"
8mm
16mm
Combi 650
-6-
100mm (4”) min.
throat depth
Panel Butt Connectors
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 cutter.
The recess is elongated to allow easy access for
the spanner. Two types are offered, plastic
ended or metal ended. Plastic ended offer better
grip.
See the latest Trend Routing Catalogue for
details.
Description Order Ref.
Panel Butt Connectors plastic ends
(pack of 10) PC/10
(pack of 50) PC/50
(pack of 100) PC/100
(pack of 1000) PC/1000
Panel Butt Connectors metal ends
(pack of 10) PC/10/M
(pack of 50) PC/50/M
(pack of 100) PC/100/M
(pack of 1000) PC/1000/M
Biscuit Jointer for the Router
Worktops with inadequate support below them
need additional stability by biscuit jointing the
edges. The Trend biscuit jointing set for the
router together with the No.20 biscuits will
ensure worktops do not sag or warp in time, see
the latest Trend Routing Catalogue for details.
Description Order Ref.
Craft Range Biscuit Jointer Set C152x1/2TC
Trade Range Biscuit Jointer Set TR35x1/2TC
Professional Range Biscuit Jointer Set 342x1/2TC
No.20 Biscuits –
Quantity 100 BSC/20/100
1000 BSC/20/1000
IMPORTANT!
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.
Gripper Clamp
Description Order Ref.
Gripper Clamps 6003010
(Two off required)
Combi 650
-7-
Carry Case
Hard wearing carry case to protect and allow
ease of carrying of the COMBI650 Jig.
Description Order Ref.
Carry Case for COMBI650 CASE/650
Fill and Seal
A solvent and silicone free coloured bonding
sealant used to seal worktop joints to prevent
moisture reaching the core material. Available
in nine colours, Fill and Seal can be intermixed
to match all laminate colour variations.
Sufficient to join four 700mm worktops, it is
supplied in 100ml flexible tubes, allowing it to
be squeezed into the joint prior to closing the
joint faces. Low odour and mould resistant the
sealant has a fast curing time of around 20
minutes.
Description Order Ref.
Black Ash FS/100/BA
China Blue FS/100/CB
Champagne FS/100/CH
Deep Buff FS/100/DB
Empire Green FS/100/EG
Oyster White FS/100/OW
Pastel Grey FS/100/PG
Polar White FS/100/PW
Terracotta FS/100/TE
Pack of 9 colours FS/100/PACK
Combi 650
-8-
ASSEMBLY
Location Bush Identification
Two location bushes are used in different holes
in the jig to align the correct template aperture
for the application.
The holes are colour coded for easy
identification with dots as follows:
Green dot – Female Joint
Red dot – Male Joint
Yellow dot – Connector Recess
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 wor ktop
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
IMPORTANT!
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.
Margin Distance
Allow 8.5mm when cutting joints. Measure or
use a batten of this
thickness to aid
setting out.
Plan view
of joints
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
PENINSULA
Postform edge
Postform edge
Male
Female
Left hand joint
Cut male with laminate up
Cut female with laminate down
Combi 650
-9-
Length Stop Arrangement
OPE RATION
Setting the Length Stop for the
Female Joint
Carry out the setting operation first:
■ Fit bushes into Red dot location holes and
offer the jig to the worktop as shown. The
Green dot location holes will be
uppermost.
■ Position the jig across the width of the
worktop. Loosely fit the length stop.
■ Fasten length stop to template so that it
traps the template across the worktop
between the Red dot location bushes and
the stop. Tighten up the knob.
■ Remove the bushes from Red dot location
hole. The template is now set to cut the
correct length of joint.
Female Joint
■ Fit two location bushes in Green dot holes.
(The Green dots must be upper most.)
Leave the length stop bush in position.
■ 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
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.
IM P ORTANT!
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.
Routing the female part of the Joint
Setting the Length Stop
Location
bushes
(Red dot)
Postform edge
Length stop on
underside.
Retained with
screw & knob
Location bushes
(Green dot)
Postform
edge
Length stop
Combi 650
-10-
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. 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 holes marked
Red dot. Face marked Red dot must be
uppermost.
■ Place template across the width of the
worktop. Clamp jig securely to worktop.
■ Cut the male joint before finally cutting the
worktop to length. All cuts must be fed left
to right.
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
cut line.
Routing the male part of the Joint
IMPORTANT!
Test fit the joints together,
abrasive paper may be required
to clean up the chipboard core.
Quick action
clamp here
Direction of
router travel
Postform edge
Location bushes
(Red dot)
*Please Note:
Out-of-square joints are possible, but the
finished joint will not be as good as a 90° joint.
Combi 650
-11-
■ Insert both location bushes into Red dot
holes. Red dot face uppermost.
■ 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.
■ 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.
■ Remove location bushes.
■ 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.
■ Clamp jig to worktop securely using quick
action clamps.
■ Remove length stop and bolt assembly as
these are for setting up only and are not
required when routing.
■ Set cutter depth.
■ Plunge router and cut the male joint, feeding
left to right in a series of shallow passes,
feeding left to right.
Cutting male
joint on out-ofsquare joints
Direction of
router travel
Postform edge
Quick action
clamp here
Shown
exaggerated
Male joint
cut line
Direction of
router travel
Postform edge
Quick action
clamp here
Setting up length stop for out-ofsquare joints
Location bushes
(Red dot)
Parallel pencil line
8.5mm from jig slot edge
IMPORTANT!
After setting for out-of-square
joint the length stop must be
removed or it could come in
contact with the router cutter.
8.5mm margin
pencil line
Male joint
cut line
Pivot point on
male joint cut line
Jig slot edge 8.5mm away
from male joint cut line
Combi 650
-12-
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 Yellow dot
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 20mm 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.
IM P ORTANT!
Best results are achieved
when the centre line of the
bolt corresponds to the
centre line of the worktop.
Clamp jig securely to
worktop.
Routing the bolt recess in the
female part of the joint
Quick action
clamp here
150mm
Location bushes
(Yellow dot)
Pencil
mark
Direction of
router travel
Underside of worktop
Quick action
clamp here
Pencil
mark
Routing the bolt recess in the
male part of the joint
150mm
Location bushes
(Yellow dot)
Pencil
mark
Direction of
router travel
Quick action clamp here
Underside of
worktop
Postform edge
Pencil
mark
Combi 650
-13-
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.
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 sealant before
assembly, to prevent moisture seeping into the
core of the worktops, which would swell and
disfigure the worktop.
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.
Cutter Ref. 342
No.20
PVA
SEALANT
Waterproof
Biscuit
Underside View
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.
Combi 650
-14-
COMBI 650
SPARE PARTS DIAG RAM
1
2
7
3
8
54 6
COMBI 650 - SPARE PARTS LIST v1.0 10/1999
Item Qty Description Ref.
1 1 Combi 650 Jig COMBI/650
2 2 Alloy Bush BUSH/650
3 1 Length Setting Stop CJ/LSK
4 0 Machine Screw Csk M8 x 50mm Slot WP-SCW/41
5 0 Washer 8.5mm x 32mm x 1.0mm 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/650
Combi 650
-15-
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 par t 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.
TROU BLE S H O OTI N G
MANU/650 v6.0
Trend Machinery & Cutting Tools Ltd.
Odhams Trading Estate St Albans Road
Watford WD24 7TR England
Enquiries: _____________0800 487363
Technical Support:_____01923 224681
Fax: _________________01923 236879
Email: ______mailserver@trendm.co.uk
WWW: _____www.trendmachinery.co.uk
© Copyright Trend 2002. 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 for m of consequential loss. E&OE
RECYCLABLE
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