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How to make a FRAME & PANEL Cabinet trend R r o u t i n g t e c h n o l o g y

A 65 page guide to using profile scribing and raised panel cutters rofile scribing and raised This booklet is intended for both amateur and Pmoulding cutters can be used to professional woodworkers and aims to outline produce traditional panelled frame the techniques involved and the basic to a professional standard. equipment required. With 1/4” shank profile scribing and raised panel moulding cutters, low powered routers (above 750 watts) can be used for this purpose. This allows anyone with basic skills, and equipment to produce high quality, decorative and attractive cabinets and fitted . Top and Bottom Rails Although for simplicity the frame rails and stiles can be of the same width, a more proportionally balanced Moulded Edges appearance can be achieved by increasing the width of The inside edges of the stiles and rails the bottom rail. Alternatively, shaping the inside edge of are grooved and moulded, the the top and/or bottom rail produces a more decorative being both deep enough to accept the appearance. The actual width of the stiles and rails is a edge of an infill panel and the stub tenon matter of visual proportion, but must be wide enough to 1 to form the frame joints. provide adequate strength in relation to the door size. Muntin FRAME & The sub-division of a door by the introduction of horizontal and vertical rails is generally dictated by its overall size, although additional strength is beneficial when constructing large doors. Wide PANEL DOOR doors normally have at least one central vertical member (muntin) to improve their appearance, provide additional strength and reduce the panels to more manageable sizes. CONSTRUCTION Stiles These must be strong enough to take the hinges, catch and handle. anelled door frames are made up Infill Panels Pof two vertical stiles and two Scribed Joint The panels can be made from solid timber, veneered or horizontal rails. The inside edge of The end of the rails are cut to form composite board. They can be cut as flat panels or with a traditional raised central area (raised and fielded panels). The the stiles and rails are grooved to the joint tenon and scribed to match the decorative rail/stile edge mould on the panel can vary from a plain to a more take the panel edge and the rail end moulding. elaborate decorative profile. tenon. trend routing technology 2 3 trend routing technology DOOR STYLES

Rectangular Flat Panelled Raised and Fielded Panel Flat Ply Panel with Muntin Flat Four Panel Curved Top Rail Cambrio Top Rail Simple rectangular frames can be fitted with Muntin Rectangular frames can be further Multi-panelled doors can be produced, By using trammels or radius jigs, the Cathedral top or cambrio shapes can be with flat plywood or MDF panels, For a more traditional style cabinet door, divided into smaller panels by adding using the profile scribing cutter to cut inside edges of the top and bottom rails produced using a pre-cut template for veneered to match the frame. a raised and fielded panel can be fitted. vertical (muntin) and horizontal rails. the scribed rail end and the profile edge of the door can be cut as a regular curve. both the rails and the matching panel Alternatively the can be These can be made using our range of This is particularly advantageous when moulding on both edges of the middle The same or a template can then be edges. Shaped panel edges can be finished with a coloured stain or . panel raising cutters (see page 42). making large doors that require more rail and the two muntins. used to shape the matching panel. easily cut using ball bearing guided rigid construction. panel raising cutters. trend routing technology 4 5 trend routing technology Profile Scriber PSC/1 PSC/10 COMPONENT DIMENSIONS 41mm Dimensions Profiling Profiling 11mm min.= min.= Frame Thickness Rail 4mm 16mm 18mm 4mm max.= max.= 6.3mm 18mm The thickness of the rails and stiles should be T T 22mm in relation to the overall door size and will therefore effect the choice of cutter. Frames for larger or heavier doors should be between 20-22mm, for smaller cabinet doors and fixed panels 18-20mm thickness. This can be PSC/2 PSC/20 Stile width (A) Stile width (A) 46mm PSC/3 41mm PSC/30 further reduced to 16mm by using the smaller Overall width (B) Profiling Profiling Profiling Profiling

11mm min.= profile/scribing cutters. A maximum frame min.= 15mm min.= min.= 3.5mm 16mm Tenon Lengths (T) 18mm 5.9mm 21mm 18mm 6.3mm 4mm max.= thickness of 26mm is possible using two of max.= max.= max.= Rail Length 4mm 18mm 9.5mm 12mm 22mm 6.3mm 26.5mm 22mm 22mm the larger profile/scribing cutters sets (Trend The length of the rail components must take into account 22mm ref. PSC/20 and PSC/40 see page 41). the length of the stub tenon at each end. The length of PSC/1 PSC/2 PSC/10 PSC/20 the tenons can be either 9.5mm or 12mm (see chart to PSC/3 PSC/4 Rail and Stile Width the right). The actual rail length is therefore: PSC/30 PSC/40 Suggested minimum width of rails and stiles The overall width of the frame PSC/5 PSC/4 PSC/40 PSC/5 PSC/50 less twice the stile width PSC/50 46mm 41mm is 40mm dependant on their specific use or to Profiling Profiling Profiling Profiling plus twice the tenon length C149 10° 11mm suit the design aesthetics. The maximum 15mm min.= or min.= min.= min.= 16mm For information on 18mm 4.7mm 21mm 18mm 6.3mm 4mm max.= width being about 60mm to 70mm. Rail length = B - (2 x A) + (2 x T) max.= max.= max.= 18mm Panel Dimensions 22mm 4mm 6.3mm 26.5mm 22mm 22mm

see page 41. 22mm trend routing technology 6 7 trend routing technology MEETING 1 To allow for the rebate, both meeting stiles must be cut wider by the width STILES of the rebate (6 to 10mm). The opposite faces of the two stiles are On cabinets with no centre partition or rebated using a straight cutter vertical frame to form a stop behind the guided by the side , or a meeting stiles of double doors, the bearing guided rebate cutter. meeting edges are generally rebated. As the width across each face of the two Cutter Ref. 46/39 x 1/4TC meeting stiles would appear uneven, it is 2 Cut a moulding along the common practice to cut a false narrow vertical edge of the front door with a line on the face of the stile. This should corner bead cutter using a diameter be equal to the gap between the meeting equal to the width of the rebate. Centre line of doors edges in order to visually balance them. 10mm 45mm + rebate (eg. 55mm) Panel 45mm + rebate (eg. 55mm)

Frame Equal thickness

Cutter Ref. 9/71x1/4TC Equal (eg. 45mm) Equal (eg. 45mm) Equal (eg. 45mm) Other sizes of corner beads are available trend routing technology 8 9 trend routing technology Chip Limiters Profile Block All Trend profile scribing and panel Profile scribing sets are available with a raising cutters are produced with range of different profile blocks, ranging chip limiting characteristics to HOLZ from a standard bevel to an elaborate 2 classic style moulding. BG standard. This reduces the risk of kick-back as the cutter enters the PROFILE and restricts the amount of Ball Bearing material that can be removed on Shims The set is fitted with a precision each cutter revolution. Each set is supplied with a set of guide bearing that guides the shims to enable fine adjustments cutter along the rail edge to SCRIBING to be made to the tightness of the determine the depth of the panel joint. This ensures that not only groove and the width of the edge accurate joints can be produced, moulding. When set up to cut the but also that the cutter set will scribe, it also determines the continue to do so throughout its thickness of the stub tenon. CUTTERS life, even with regular honing. ounted on an arbor, the Mcomponents of the profile Groover scribing cutter sets are Arbor The standard panel groove is 6.3mm The cutter set is mounted on (1/4 inch) wide, although a 4mm groove, arranged to cut the reverse a precision arbor with either Please Note. suitable for thin plywood, glass, brass 6.3mm, 8mm or 12.7mm shank scribe on the rail ends, before Profile Scribing cutter mesh or fabric covered panels, can be diameter. The profile block, sets should only be achieved using our cutter sets supplied being rearranged to cut the groover and ball bearing are used in a table. with a 4mm groover. matching profile and panel secured on the threaded Chip limiter section by a nut and washer. 1.1mm groove along the inside edges. trend routing technology 10 11 trend routing technology PROFILE SCRIBING CUTTER ASSEMBLY Cutter set-up for scribing Parts supplied in profile Cutter set-up for profiling Which Router? scribing cutter set Profile Scribing operations should only 1. Arbor with 1/4”, 1/2” or 8mm shank be carried out using a router of 750 2. Nut (13mm A/F) 3. Profile Block watts or over, fitted to an inverted or 4. Groover 1 overhead routing table. Profile 1 5. Ball Bearing 22mm diameter Scribing cutters are now available with 6. Washer 1.0mm (x1) Fine Height Adjuster 7. Shims 0.1mm (x3) 6.3mm (1/4 “), 8mm and 12.7mm (1/2 “) 8. Shims 0.05mm (x3) arbor shanks, suitable for use in most Collet Size To allow precise adjustment of the cutter 9. Spacers 1.0mm (x2) (PSC/20, PSC/40 current routers, although the profile An optional collet size of 8mm is now height to accurately align the mating only) available for many routers enabling profiles of scribed joints, it is essential to 10. Shim 0.5mm (x1) (PSC/20 & PSC/40 variations in the smaller sizes are at 4 fit a fine height adjuster to the router. 7 only) present limited. many, in particular the smaller machines, 8 The set is supplied in scribing mode. 3 to use all the profile scribing cutter sets 10 However parts ➂ and ➃ should be 7 9 within the range. The 8mm shank is 8 Variable Speed 5 assembled to each other to reduce PSC/40 only 4 Although variable speed control is more rigid than 6.3mm shanks, and Use with PSC/20 & 9 cutting impact. recommended, it is not essential when 8 Shims, part no’s ➆ and ⑧ are used to 7 therefore beneficial for use in smaller 7 8 using profile scribing cutters. It is adjust the tightness of the joint. routers. 5 necessary however to reduce the speed 3 The ball bearing diameter determines the 6 when using panel raising cutters of 50mm 6 depth of cut. 2 2 diameter or above. trend routing technology 12 13 trend routing technology FLAT CLASSIC SETS PROFILE SCRIBING CUTTER SETS Groover Material thickness Ref. Shank Diameter

6.3mm Kerf 18mm to 22mm PSC/3 8mm 1/2” There are five styles of Profile 4.0mm Kerf 16mm to 19mm PSC/30 8mm 1/2” Scriber Sets, each available with 6.3 or 4mm kerf groovers and on 8mm or 1/2” shank diameters. CLASSIC SETS Groover Material thickness Ref. Shank Diameter 6.3mm Kerf 18mm to 22mm PSC/1 8mm 1/2” CLASSIC SETS 4.0mm Kerf 16mm to 19mm PSC/10 8mm 1/2” Groover Material thickness Ref. Shank Diameter

C149 as PSC/1 but with 6.3mm diameter shank 4.0mm Kerf 18mm to 22mm PSC/4 8mm 1/2”

6.3mm Kerf 21mm to 26.5mm PSC/40 8mm 1/2”

CLASSIC SETS Groover Material thickness Ref. Shank Diameter

4.0mm Kerf 18mm to 22mm PSC/2 8mm 1/2” 6.3mm Kerf 21mm to 26.5mm PSC/20 8mm 1/2” BEVEL SETS Groover Material thickness Ref. Shank Diameter

6.3mm Kerf 18mm to 22mm PSC/5 8mm 1/2”

4.0mm Kerf 16mm to 19mm PSC/50 8mm 1/2” trend routing technology 14 15 PROFILE The Profile Scribe Multi Set contains interchangeable cutter blocks to allow three PANEL DOOR SETS Ref. PDS/1 SCRIBER different mould styles to be used. By using the extra groover, a 1/4” tongue and

MULTI SET groove joint can be made. Maximum Ref. PDS/2 thickness of material for is 22mm. Ref. PDS/3

Ref. PDS/4 Trend panel door sets each consist of one profile scriber cutter and one PANEL DOOR SETS Contents Ref. Shank Dia. matching raised panel cutter. The 1/2” Ref. PDS/5 PSC/1 & 18/83 PDS/1 1/2” shank sets are intended for use in PSC/20 & 18/83 PDS/2 1/2” PSC MULTI SET - PSC/MS1 Timber thickness heavy duty routers. The 8mm shank PSC/3 & 18/82 PDS/3 1/2” Comprises Qty. Ref. Ref. PDS/10 Min = 18mm cutters can be used in routers over PSC/40 & 18/81 PDS/4 1/2” Max = 22mm Profile Scriber Set 1 SP-PSC/1 750 watts, fitted with a 8mm collet. PSC/5 & 18/80 PDS/5 1/2” For use in a router Profile Block 1 SP-PSC/3A There are maximum speed constraints PSC/1 & 18/24 PDS/10 8mm table only Profile Block 1 SP-PSC/5A Ref. PDS/11 PSC/2 & 18/24 PDS/11 8mm 6.3mm Groover 1 SP-34/70TC on the following 1/2” shank panel PSC/5 & 18/20 PDS/12 8mm Spare Spacer Set 1 SPACER/8 cutters. 18/82 & 18/83 16,000 RPM Ref. PDS/12 trend routing technology 16 18/80 & 18/81 12,000 RPM 17 trend routing technology MATERIALS Before purchasing the timber for rails, stiles and Preparing the timber helpful when alternating the grain panels, consider the following points: 1 Cut and all timber to the pattern of each adjacent piece when 1 Calculate the amount required carefully required sizes, finishing it square and edge to form the panels (see 3 allowing for adequate waste. Remember to true. page 38). add extra length to stiles to leave horns to 2 Carefully cut all components to 4 To avoid confusion when cutting protect the corners of the door before fitting. MATERIALS length, allowing extra length on the batches of similar components, 2 Take care to select straight grained timber with stiles to form horns. ensure that there is adequate no dead or loose knots, matching each board stacking areas for feeding into and 3 Mark all face sides and edges for & OTHER for grain pattern and colour. taking off, adjacent to the table. easy reference. This is particularly 3 Always check that the timber is fully seasoned important to ensure that each piece EQUIPMENT with a low moisture content to avoid excessive is correctly set up on the router table shrinkage. for cutting the scribe and profile parts of the frame joints. It is also o obtain accurate results from Traditional face and Tyour profile scribing and panel edge marks applied raising cutters, always select good for easy reference. quality timber and equipment. trend routing technology 18 19 trend routing technology OTHER EQUIPMENT Please Note. Dust Extraction No-Volt Release Switch Dust and waste extraction equipment is dust and waste material to be extracted Profile scribing cannot be carried It is recommended that all router tables Inverted Routing Table recommended for all table routing directly from behind the cutter. out safely or satisfactorily using are fitted with a No-Volt Release Switch. Throughout this booklet, we show operations operations, particularly when routing Many vacuum extractors allow a router the cutter assembly in a router, The switch should be secured to a leg or being carried out on the Trend ‘Craftsman’ man-made materials such as Medium (up to 1800 watts) and the extractor held and guided by hand. the table edge to provide immediate router table. This table is designed to take Density Fibreboard (MDF). motor to be switched on and off access to the on/off buttons. Should the virtually every make and model of router. Most proprietary routing tables are fitted simultaneously. power supply be turned off or fail at Supplied with a 230 Volt No-Volt Release with an integral dust collection port source, a No-Volt Release Switch will Switch and pushstick, it can also be fitted in the back fence. This allows the prevent the router from re-starting until with a number of optional accessories. the green on-button is pressed.

trend routing technology 21 trend routing technology MAKING A 2 an end stop to the to WORKHOLDER form a precise right angle to the fence. To cut the scribed rail ends, the rails must 3 Screw a toggle to the stop be presented at 90° degrees to the fence. THE SCRIBE to hold the workpiece firmly. For both accuracy and safety, it is THE SCRIBE ______23 - 27 The stop batten also acts as a spelch The profile scribing cutter is recommended that a purpose made block to prevent breakout as the cutter MAKING A WORKHOLDER workholder is used. first set up to cut the joint breaks through. Alternatively, a tenon and the matching SETTING UP THE CUTTER 1 Cut a 6mm baseboard, at least 75mm parallel waste batten can be held reverse moulding (the scribe) CUTTING THE SCRIBE wide (to prevent the workpiece turning between the rail and stop batten to to fit into the rail edge or snatching as it enters and leaves the perform a similar function. groove. cutter).

THE PROFILE ______28 - 30 If your table is SETTING UP THE CUTTER fitted with a sliding mitre fence, it is CUTTING THE PROFILE still advisable to use a workholder of this type to THE SHAPED RAILS______31 - 33 support the workpiece, rather WORKHOLDER FOR TRIMMING than holding it FRAME CUTTING THE EDGE PROFILE against the face of 4 the mitre fence. trend routing technology 22 23 trend routing technology 1 On first use or when reassembling the Make a Trial Joint 3 Setting the depth of the cutters on the arbor, position the Before using your profile scribing Quirk cutters (parts 3 & 4, as shown on page cutters on a specific project, always When setting the cutter height be 12) at 90° degrees to each other and cut a series of trial joints using sure to leave an adequate depth check that the arbor nut is tight. Do waste material, the same quirk on the moulding of at least not hold the cutter assembly in a vice dimensions as that to be used for 1.5mm. Any less will result in a or with pliers etc, as this will damage the stiles and rails. Having cut a weak edge that may lose definition the cutting edges or shank. successful well fitting sample joint, when sanded or painted. keep it in the workshop for Always machine the timber with the reference on future projects. cutters set in this way (as below). SETTING UP 2 Adjusting the Height THE CUTTER 1.5mm 4 Aligning the cutter Fit the cutter assembly into the router minimum To align the fence and ball bearing, When forming scribed frame joints it ensuring that at least three quarters of loosen the fence clamping and is common practice to cut the scribed rail the shank length is gripped in the apply a steel rule across the faces. ends first. This eliminates the breakout collet. Set the height of the cutter Slide the fence back until the rule edge that would otherwise occur on one end of above the table allowing the bottom touches the bearing. On tables with edges of the cutter to cut slightly into each stile when cutting the edge moulding 4 3 adjustable facings, close these to leave the top face of the baseboard. and groove. approximately 3mm either side of the Our profile cutters are therefore supplied 90¡ cutter to allow waste to clear freely. arranged for cutting the scribe. trend routing technology 24 25 trend routing technology CUTTING THE SCRIBE Save Time Make the following checks: To avoid re-assembling the cutter FACE-SIDE UP unnecessarily, cut all the scribed Check that all guards are fitted, correctly 1 rail ends first. Then change the cutter positioned and secured. set-up to cut the stile edge profiles. 2 Check the dust extractor is connected. 3 Remember to position the rail in the workholder FACE-SIDE UP when cutting the Scribe. 4 Check that the collet and arbor nuts are secure. 5 Check that the cutter will revolve freely and that there is clearance around the cutter for chips to clear.

1 Clamp the rail in the workholder, aligning one end against the fence. 2 Switch on and allow the router to reach full speed. Feed the work in a smooth continuous Scribe cutter set-up Slide the workholder up to the face of the in-feed fence, keeping your hands movement across the cutter, keeping the rail away from the cutter. end tight to the fence face and the workholder baseboard flat to the table. trend routing technology 26 SETTING UP THE CUTTER 6 In order to reduce the depth of cut cutter profile to the scribed profile, 11Ensure the fence is aligned with the when using 1/4” shank cutters, the aligning the groover with the stub bearing using a steel rule as before. For profiling the rail and stile edges, set up fence should be set forward of the tenon and the quirk with the profile the cutter in the following sequence: bearing face for the first pass, then block. 1 Disconnect the router from the power aligned with it for the final one. 10 Remove or re-arrange the shims source. between the cutter components to 2 Leave the arbor in the collet and use tighten or loosen the joint and adjust the routers lock or spanner to the cutter height to leave the rail and prevent it turning while undoing the stile faces flush. nut. Profile cutter set-up. See page 12 for full details. scribed rail end Pressure Clamps THE EDGE For both accuracy and safety, it is 7 If fitted, close the adjustable fence recommended that vertical and/or horizontal 3 Re-arrange the cutter components in facings to leave a gap of approx. PROFILE router table pressure clamps (hold down clamps) are the correct order for cutting the edge 3mm either side of the cutter. fitted. These must be adjusted to maintain By re-assembling the profile profile. 8 Lay the pre-cut scribed rail end on the Cutter set up firm pressure between the fence or table and scribing cutter, the edge for profiling moulding and panel groove 4 Fit the shims between the cutter table, FACE-SIDE DOWN (i.e. the timber, but still allow the work to be fed components using the scribed rail opposite way up than when cutting smoothly and evenly across the cutter. can be accurately cut to ends as a guide. the scribed rail ends). Always use a push stick or workholder to produce a precise and feed the work into and out of the cutter. strong joint. 5 Loosely tighten the arbor nut for the 9 Adjust the cutter height using the fine moment. adjuster and match the reassembled trend routing technology 28 29 trend routing technology CUTTING THE PROFILE WORKHOLDER FOR TRIMMING

1 Check that all guards are fitted, When profile-scribing The template must be cut overlength to correctly positioned and secured. curved and shaped allow the cutter to be fed smoothly into 2 Check that the dust extractor is rails, it is advisable and away from the cutter. A lead-on pin connected. to cut the scribed or piece should be fitted to the table to 3 Switch on and allow the router to reach joint before shaping the prevent the end of the workpiece from full speed. rail edge. The rail edge can being snatched into the cutter. then be cut to the required curve or 4 Position the workpiece FACE-SIDE Trimming the rail to shape: DOWN with the FACE-EDGE against shape using a template/workholder, with Roughly cut the rail to shape with a the back fence, clear of the cutter. its leading (guide) edge cut to the 1 or , taking care not to required curve or shape. For safe damage the scribed rail ends. Leave Cutting the edge profile on the trial piece handling, the workholder is fitted with a maximum of 3mm for trimming. handles and/or guards and is initially SHAPED 2 Ensure that the rail is gripped in the 5 Slide the workpiece under the in-feed used to trim the rail against a bearing workholder, if necessary locating it pressure clamp. RAILS guided trimming cutter. with veneer pins or double sided tape. Using the pushstick or a workholder, A rear locating batten and lead-in and Face-side down 6 3 Fit a trimming cutter which has a When cutting curved and feed the rail across the cutter in a lead-out end blocks, fitted to the suitable length of cut. smooth continuous movement, keeping shaped rails, it is advisable to underside of the template, locate the the rail tight to the fence face. make up a combined template workpiece beneath the template. and workholder to ensure safety and accuracy. trend routing technology 30 31 trend routing technology CUTTING THE EDGE PROFILE Jig Template Handle The sequence for cutting the profile on 5 Check that the trial piece produces a shaped and curved rails and stile edges is flush joint when assembled, before Lead-out The curved rail edge after cutting Lead-in Rail block as follows: cutting the remaining rails. block the moulding and groove. Handle Replace the trimming cutter with the max. 1 3mm Template profile scribing cutter arranged to cut the edge profile. Rail Back and end locating 2 Use the pre-cut scribed rail end to set blocks the cutter height. 3 Re-fit the cutter guard and locate a trial Router Table surface workpiece in the workholder, with the FACE-SIDE DOWN to the table (as for 4 A suitable guard must be fitted above the exposed edge profiling straight rails). cutter when carrying out any template profiling Starting with the lead-in block of the operation. 4 workholder resting against the lead-on 5 Switch on and carefully feed the workholder onto pin, feed it into the cutter. Follow the cutter via the lead-on pin. Make a second through in a smooth continuous pass to ensure a clean cut has been produced. movement along the length of the rail and partially into the lead-out block. trend routing technology 32 33 trend routing technology rofile scribed frames can PANEL STYLES be fitted with either plain Relief moulded Panels THE P Cut from MDF sheet, these have or decorative moulded panels a decorative relief moulding cut made from solid timber or into the surface, either to form a boarder parallel to the edges or timber based sheet materials. as a pattern across the panel PANELS surface. Panel moulding cutters However, all panels must be of stable 5 Plain flat panels are used to machine the materials or constructed to eliminate any Cut from Medium Density moulding, guided by a template Fibreboard (MDF), plywood or and guide bush, straight edge excessive movement that may result in other timber based sheet or the side fence. twisting or warping of the panel and frame, material. These materials can either be veneered to match or shrinkage of the panel within the frame. the frame timber or left plain for painting. Panels must be of suitable thickness for the overall frame size and have a finished Tongue and groove edge thickness that is a sliding fit in the match boarding ______panel groove, but not too tight as it may Either v-jointed or with a bead PANEL STYLES 35 profile, the boarding can be cut cause the rear groove edge to curl to length and if thicker than the JOINTING ______36 - 37 outward. groove, rebated to fit. Where the panel material is thicker than Raised, fielded and ______the panel groove, the edge can be either moulded panels ASSEMBLING 38 - 39 These traditional panel boarders rebated on one or both faces, or raised and can be simply cut using the router fitted with a panel raising cutter TRIMMING ______40 - 41 fielded on the front face, using panel selected from the Trend range. raising cutters. trend routing technology 34 35 JOINTING

The four most common Round methods used for jointing Small diameter (6mm) round dowels are panels are traditional inserted into equally spaced holes drilled rubbed joints, biscuit along the joint edges, using a proprietary dowelled joints, round doweling jig. This ensures that the holes dowelled joints and loose tongue joints. are drilled at right angle to the edge and Grooves Biscuit Dowelling correctly aligned. Lip and spur dowelling A router can be used to cut grooves for Biscuit or elliptical dowels, can be , for use in machines and Rubbed joints loose tongues, 6mm into each mating These are formed by the mating used to reinforce edge-to-edge panel routers, and splined dowels (grooved to edge, using either a narrow straight cutter, edges perfectly straight and true before joints. The dowels are set into semi- allow excessive glue to be released) are guided by one or two side fences to centre applying glue and rubbing the two edges circular recesses cut with the router fitted available from Trend. the cutter across the timber, or a ball together to spread the glue evenly. The with a suitable grooving cutter (See Trend bearing guided grooving cutter. Stop the joint is then clamped until dry. Biscuit Cutter Set, Ref. 342). The groove clear of the panel mouldings at positions are carefully set out at approx each end to avoid showing the groove on 150mm centres along the joint faces, but the face of the panel raising. Secure the carefully avoiding the width of the panel joint with a 10 mm wide cross grain raising mould at each end of the panel. tongue, equal in thickness to the groove width. trend routing technology 36 37 trend routing technology ASSEMBLY Gluing and Cramping When joining solid timber In order to keep thin panels flat while plane and/or sand the surface flat on boards or strip, edge-to-edge Glued panel gluing and cramping: one face. Mark the finished panel finished to to form panels, alternate the consistent 1 Cut two pieces of thick sheet material thickness along each edge and thickness direction of the growth rings (MDF, Plywood, Chipboard etc.), plane/sand the other face. to minimise cupping and Alternate growth ring direction of adjacent boards slightly smaller than the assembled Ensure that all traces of glue bowing across the glued-up panel. are removed from both board. Preparing the Timber 2 Cover the boards with polythene surfaces. sheet to prevent excess gluing Each pair of mating edges must be adhering to them. planed straight and square to ensure that Glue the edges and assemble the the joint will be virtually invisible and that 3 panel on one board. the panel will be flat when released from Lay the other board over it and the cramps. 4 position cramps around the Carefully arrange adjacent boards or perimeter, but do not fully tighten. strips so that the grain pattern along the Use sash cramps or webbing straps joint lines blends and follows the same 5 to pull the panel joints tight before direction. Alternatively arrange the grain finally tightening the edge cramps. pattern to produce decorative book When dry, release the cramps and matched or ‘flame’ pattern effects. 6 trend routing technology 38 39 trend CALCULATING THE PANEL SIZE

Assemble and clamp each (following the grain direction) twice 2 Alternatively a 6mm margin can be 3 Frames and panels made from stable 4 Plane one edge of the panel straight frame and measure the inside the depth of the panel groove minus deducted from both dimensions, but timber based materials (i.e. MDF) can and finish one end at right angles to it. dimensions using a tape 2mm. Add to the width of the panel this may require the panel to be fixed be cut to fit. These panels can then be 5 Transfer the dimensions then cut and measure or by marking off (across the grain) twice the depth of in the panel grooves to prevent it glued directly into the frames. plane the panel to size, finishing the along a straight batten the panel groove minus 6mm. This is (setting out rod). from dropping (see page 58). Groove depth edges square and parallel. to allow for movement across the 46mm groover = 12mm Panel margins for calculating overall panel 41mm groover = 9.5mm sizes when using profile scribing cutter width of the panel (the direction in Shaped top panel fitted with either 46 or 41mm groovers. which most movement will occur) Square top panel For solid timber panel: while preventing it from dropping 46mm diameter groover = vertically. A = x + (2x12mm) - 6mm Groove depth: 46mm groover = 12mm B or C = y1 or y2 + (2 x 12mm) - 2mm 41mm groover = 9.5mm 41mm diameter groover = A = x + (2 x 9.5mm) - 6mm B or C = y1 or y2 + (2 x 9.5mm) - 2mm

B C For plywood or MDF (i.e. stable materials): Always ensure that the 46mm diameter groover = edge thickness/profile A, B or C = x, y1 or y2 + (2 x 12mm) - 1mm produces a sliding fit in x Grain direction 1 For solid timber frames and panels, the groove. 41mm diameter groover = y2 y1 A, B or C = x, y1 or y2 + (2 x 9.5mm) - 1mm. add to the length of the panel For solid timber panels allow: Rails 3mm A Stiles 1mm trend routing technology For MDF or Plywood panels trend routing technology 40 allow 1mm clearance all round 41 RAISED PANEL VERTICAL RAISED PANEL CUTTERS When using vertical panel raising cutters A deep horizontal front pressure guard or in inverted routers, it may be necessary vertical support will help ensure safety MOULDING CUTTERS (not on Craftsman router table) to fit an and accuracy by keeping the bottom edge 6 extended height false face to the back of the workpiece flat against the fence fence, to support the workpiece vertically. face. VERTICAL ______43 BEARING ______44 HORIZONTAL ______45 RADIUSED ______46 ______47 he traditional panels for the doors can be OVOLO & CLASSIC _ 48 Trouted using panel raising cutters held in a fixed position router. The router can be BEVELLED ______49 mounted either overhead or inverted in a table. The material is then passed into the cutter in a Positioning the vertical front support block series of shallow passes to build up the mould. trend routing technology 42 43 trend routing technology BEARING GUIDED RAISED PANEL CUTTERS HORIZONTAL RAISED PANEL CUTTERS

Straight, or shaped panels can be Large diameter horizontal raised panel stop to increase the cutting depth for moulded (raised) by running the panel cutters are used for moulding straight each. Likewise, wider mouldings can be against the ball bearing or the edge of a edges against the table fence. It is produced by resetting the fence to allow template mounted above or below it. advisable to use them only in table the cutter to cut in a series of passes However, the edge of the panel must be mounted variable speed routers at their cutting further in from the edge on each finished as a smooth, continuous edge, recommended safe speed. pass. When using a router table with a as the ball bearing will follow any Initially, templates can be cut using a Cutters above 50mm in diameter, should cutter aperture smaller than the cutter unevenness, repeating it on the finished trammel or ellipse jig, relying on the be used at speeds not exceeding 18,000 diameter, always fit a false top to allow moulding. If required, the back fence can router cutter to leave a smooth square rpm, above 70mm diameter at 16,000 the cutter to be set slightly lower than the be used when cutting straight edged edge. Alternatively, the template can be rpm and above 80mm in diameter at surface (see page 51). panels to provide additional stability. cut with a jigsaw and the sawn edge 12,000 rpm. 2nd PASS 1st PASS When cutting curved work, the ball finished square with a plane or . When using horizontal bearing can be run against either the When using ball bearing guided cutters raised panel cutters, never shaped workpiece itself or against a on an inverted router table, it is necessary cut to the full depth in one template (cut from 6.3mm thick material to fit a false table top to allow the cutter pass. The full depth FALSE TOP SIDE FENCE (MDF, Tufnol® etc.), fixed to the top face to sit fractionally below the surface. (See should be reached in a of the workpiece with a purpose made jig, page 51). series of shallow passes, TABLE pins or double sided tape. using the routers turret trend routing technology 44 45 trend routing technology RADIUSED PANEL MOULDING CUTTERS OGEE PANEL MOULDING CUTTERS

Ref. 18/24

Ref. 18/23

Ref. 18/81 Ref. 18/91 Ref. 18/83

D

R C Ref. 18/84 Ref. 18/21 OGEE PANEL MOULDING CUTTERS Ref. 18/93 RADIUSED PANEL MOULDING CUTTERS Ref. R D C Shank Diameter Ref. R D C Shank Diameter 18/24 12mm 50mm 14mm 1/2” 18/81 40mm 86mm 12.7mm 1/2” 18/83 17.5mm 67mm 16mm 1/2” 18/91 40mm 28.5mm 38mm 8mm & 1/2” D 18/23 6mm 50mm 14mm 1/2” d 18/21 14mm 50mm 14mm 1/2” 18/93 22mm 30mm 38mm 8mm & 1/2” C 18/18 50mm 73mm 22mm 1/2” R Ref. 18/25 Ref. 18/18 18/84 22.2mm 85.7mm 15.9mm 1/2” R trend routing technology 46 18/25 3mm 50mm 14mm 1/2” 47 trend routing technology MODERN OVOLO & CLASSIC MOULD BEVEL MOULD RAISED PANEL CUTTERS PANEL CUTTERS

Ref. 18/26

Ref. 18/82 Ref. 18/80 Ref. 18/90

Ref. 18/22 Ref. 18/20

MODERN OVOLO & CLASSIC MOULD PANEL CUTTERS BEVEL MOULD RAISED PANEL CUTTERS D Ref. A R1 R2 D C Shank Diameter Ref. A D C Shank Diameter 18/26 3¡ 6.3mm 3.2mm 45mm 13.5mm 8mm 18/80 15¡ 86mm 12.7mm 1/2” D C 18/82 5¡ 8mm 3mm 63.5mm 12.7mm 1/2” 18/90 75¡ 28.5mm 38mm 8mm & 1/2” C 18/22 - 3mm - 50mm 14mm 1/2” 18/20 10¡ 50mm 17mm 1/2” R1 A R2 A 18/92 85¡ 3mm 8mm 25.4mm 38mm 8mm & 1/2 Ref. 18/92 18/19 25¡ 69mm 19mm 1/2” Ref. 18/19 trend routing technology 48 49 trend routing technology SETTING UP aised panel cutters are Before using cutters larger in mark out any existing holes that can ensuring that there is a minimum of used to cut away the R diameter than the router table be used to fasten the false top. If not, three quarters of the shank length panel edge to fit into the aperture, it may be necessary rail or stile groove, set out two suitable positions to take held in the collet and that the bottom to lay a false top over the 7 producing a decorative fixing bolts. edges are set fractionally below the router table, to allow the bevel, radius, ogee or 3 and counter-bore the fixing holes surface of the false top (not touching bottom of the cutting edges ovolo moulding. in the false top to match the holes in the router table). USING to be set lower than the table surface. the existing top. RAIRAISED 4 Mark the centre point of the existing table cutter aperture on the false top and drill/cut fixing holes or slots for PANANEL SETTING UP ______51 FALSE TOP the existing back fence. TABLE 5 Add 6mm to the diameter of the CUTTERS MAKING A TEMPLATE __ 52 cutter and cut the cutter aperture to that diameter. 8 Refit the back fence (replacing the COMBINED JIG ______54 6 Fasten the false top on the table. mounting bolts with longer ones as 1 Cut a piece of 6 to 12mm medium 7 With the router disconnected from necessary) and mount the holding ______density fibreboard (MDF) to the same SCORING 55 the power source and the fence down guards. Check that all are size as the table top. removed, fit the cutter from above, correctly adjusted and secure. LEAD-ON PIECE ______56 2 Place it over the router table top and trend routing technology 50 51 trend routing technology MAKING A 3 To the outline drawn on the template 5 Finish the straight edges with a plane and the TRIMMING TO SIZE material, add the required groove curved or shaped edges with a or TEMPLATE width (see page 32) and draw a line abrasive. Check that all edges are smooth, as any unevenness will be repeated on the finished work For accuracy, curved and shaped outside and parallel to the outline. panels should be cut using a when trimming with a ball bearing guided cutter. template cut to fit into the frame. 6 Check that the margins are correct by This reduces the risk of ruining the re-assembling the frame, with the template fitted. actual panel material and speeds 7 Lay the template on the uncut panel and mark out up the work when cutting several the outline. or a batch of similar panels.

1 Clamp the dry assembled door frame over a piece of 6mm thick sheet 4 Carefully cut around the outer line 8 Cut the panel roughly to shape with a jigsaw or material (plywood, MDF etc.) and with a jigsaw, or for regular curves, 9 Trim the panel flush to the template edge using a ball band . check that it is square and flat. with the router fitted with a beam bearing guided template profiling cutter. Although the 2 Carefully draw round the inside edge. trammel. router is shown fitted to an inverted router table, it can also be used for trimming in hand-held mode. trend routing technology 52 COMBINED JIG SCORING

After trimming and squaring the panels, select If the cutter persists in tearing the grain, score A combined jig for cutting Templates can be cut from multi- and mark the face side. Whether cutting across the cut line with a sharp knife, the width both the rail and panel shape core plywood, MDF or preferably Tufnol® straight, curved or shaped edges, always cut of the cutter in from the edge of the workpiece can be made, consisting of sheet to the required shape or curve. For the raised edge moulding, first across the grain (i.e. distance from the outer tip of the cutter to two matching templates fitted safety and accuracy extend the curve before cutting the moulding along it. This will the bearing or fence). to a baseboard. either side of the required length or remove any break out left by the cross grain shape. These lead-in and out sections, cut. allow the cutter to enter and leave the work smoothly without snatching. The template can be pinned to the component Scoring across the into the waste of the stub tenon to avoid end grain marring the face of the wood. Cut the curved rail/panel using a ball bearing guided straight profiling cutter.

trend routing technology 54 55 trend routing technology LEAD-ON PIECE Top Guard Panel Cutter SUMMARY OF SAFETY TECHNIQUES Lead-on piece Preparation: switch to inverted or overhead length is held in the collet). When moulding curved or shaped raised tables). ● Ensure groovers are correctly ● Always use guards to ensure there is ● Ensure that all power leads are clear assembled and nut is tight. panel edges, using ball bearing guided no possibility of fingers contacting of the table and cutter. Check they ● Practice the cutting procedure before cutters, a lead-on pin (as on our Adjusting screws and the cutter should your grip slip or the mounting brackets cannot catch on the work or switching on the router. Craftsman table) or lead-on piece, must cutter snatch. workholder or interfere with the ● Keep fingers clear of the cutter and ● If in doubt always take more shallow be fitted to prevent the work from being movement of, or trip the operator. never touch the router or cutter to passes rather than fewer deeper cuts. snatched into the cutter. ● Always wear eye protection such as slow the machine down. ● Reduce the speed of the router when goggles or a full face visor. Always ● Do not switch on the router with the A lead-on piece can be cut in the Feed Direction using cutters over 50mm in diameter. wear ear defenders particularly if workpiece in contact with the cutter. workshop from waste plywood or ● Use a lead-on pin when carrying out routing for lengthy periods. ● Always feed the timber into cutter to and securely mounted on the curved work. ● Do not wear loose clothing or oppose the direction of the cutter. ● Measure twice cut once. router table (or the false top). The lead- jewellery that can catch or snag on ● Take care when handling cutters as on piece should be fitted close to the cutters or equipment. Always tie they are sharp and can easily cause Cutter Rotation back long hair. cutter to provide a rest or pressure block injury. so that the workpiece can be steadied ● Always switch off the router and Final checks: isolate from the mains supply before Back fence against as it is fed into the cutter. A ● Check that all guards are correctly changing cutters or making lead-off piece can also be fitted to and securely fitted. adjustments to the router, table or support the work as it leaves the cutter. ● Check that the dust extraction is machining set-up. connected. ● Before reconnecting to the supply, ● Check that the cutter is correctly make sure that the power switch is in fitted (i.e. at least 3/4 of the shank Timber Feed the OFF position (fit a no-volt release trend routing technology 56 57 trend routing technology Gluing the panels Clamping Finishing are and attention is Before gluing the work together, assemble Unless made of MDF or other stable 1 To protect the surface from the If the doors are to be given a clear finish, Cessential when gluing and the frame dry and mark each piece of each material, panels should not be glued into cramp jaws, insert ply packing or a it is very important not to leave traces of assembling doors, in order that joint for easy reference. the frame. However, it is possible to continuous batten between the cramp glue on the surface. When gluing the they remain square and true 8 1 Check that the panels will fit into the secure timber panels with two brass heads and door edge. To stop the joints together try to judge the amount of when fitted. Always apply glue grooves without being forced, otherwise veneer pins at the centre or each rail. bar of the cramp scuffing the face of glue used so that it just forms a thin line sparingly to avoid leaving the whole door will be difficult to This allows for movement of the timber the door insert a thin piece of on the surface that can be cut off later. If traces on surfaces that are to be varnished. assemble and edges may split away. while the pins prevent the panel rattling plywood along each stile. the glue runs onto the surface thoroughly DOOR 2 All of the surfaces that cannot easily be in the frame should it shrink. 2 Before leaving the glue to set, check wipe this away with a damp cloth making sanded after assembly, should be that the door is square, by measuring sure that the glue is completely removed finished before gluing up. Be careful Pinning the panel across the diagonals and checking from the grain as well as the surface. If Do take care when inserting pins, not to when sanding the inside edges that the that it has no twist, using winding this is not done properly any stain or ASSEMBLY split the thin groove edge. Preferably location marks for the rails are not strips to sight along it. polish subsequently applied may drill fine pilot holes and drive the pins at sanded away. highlight the area in the form of a white an angle into the thicker part of the edge 3 Prior to gluing, place across the stain. top of the bench for the door to rest on. moulding. File and punch the pins below This will allow the cramps to be the surface. As an allowance has been positioned far more easily. The top edge made for the panel to move, make sure it of the battens must be perfectly level in is centred and square before pinning it order that the door will be flat when into the frame. trend routing technology 58 cramped. 59 trend routing technology HINGES Flap hinges unrestricted access. These hinges have similar way to concealed hinges, using a Traditional solid drawn or plated flap a circular boss that is sunk into the door template to position the cutter over the hinges can be used where the door is set Router fitted with panel and are available in either plain or face edge of the door and carcass. straight cutter flush into the cabinet carcass. Flap sprung versions. The latter eliminates hinges are set into recesses cut in the Guide Bush fitted to base the need for a separate catch or lock. Machining the holes cabinet side and door stile. These of router They are available with various boss recesses can again be cut with the diameters, although 35mm is the most router, using a simple template and guide Concealed hinges common. bush. The type of hinge used on doors depends The size and type of hinge chosen will on the construction of the cabinet, its depend on the size and weight of the Cramp location and use. When used on kitchen door itself. With flap hinges the Hinge Template cut from and other fitted cabinets, where the door 6mm MDF and screwed thickness of the door style in relation to to clamping batten covers part or all of the cabinet frame, it the flap width will dictate the hinge size is common practice to use concealed Our new range of machine bits are for use in used. Economy lay-on hinges are only Lay-on hinges hinges. portable plunge routers. These specially suitable for lightweight doors up to Lay-on hinges are commonly used for These are generally designed to open to designed machine bits have a new form of scriber to allow use at high speeds, Max. 450mm wide. Concealed hinges will economy cabinet construction, being an angle of 100 degrees, although special Fall Flap hinges 20,000 RPM. For accurate repetitive routing, a simply screwed to the inside face of the Fall flap hinges (as used on desks and support larger and heavier doors and are lay back examples allow the doors to template and guide bush fitted to the router light duty work flaps) are fitted in a fully adjustable once fitted. cabinet or frame and the stile edge. open clear of the cabinet sides to allow base should be used. Ref. 105 group.

trend routing technology 60 61 trend routing technology EDGE MOULDING MAKING ROUTER CARVINGS

Using the Trend Router Carver panel doors, kitchen doors, corner system, authentic frames, handle surrounds, door rails designs can be added onto the panels and rosettes. of cabinets and kitchen doors. The Various templates are offered for system comprises a unique engraving different applications. The primary Ref. 7/4 Ref. 46/41 Ref. 7/81 Ref. 22/01 Ref. 19/62 cutter housed in a conical bearing designs, Classical and Royal, continue guide together with a set of templates through the entire range providing a Where cabinet doors are to be fitted to When edge routing doors with raised and template frames. The templates continuity of style. the face of the carcass or frame, a further panels that are higher than the frame have slots to guide the cutter both attractive effect can be achieved by face, it is advisable to fit a packing piece horizontally and vertically, producing routing a or decorative moulding to the underside of the router to support variable depth carvings. A range of around the outer edges. it on the frame face rather than the panel attractive designs are offered to suit Choose a moulding of similar style to the face. When using the side fence, it is profile moulding cutter and/or raised advisable to extend the fence facings panel cutter and of similar size. (cheeks), in order to prevent the cutter Edge moulding the glued panelled door using a ball bearing guided Edge moulding can be quickly carried out from turning in as it starts and finishes Ovolo cutter. with cutters guided by the side fence or the cut at each end of the stile or rail. using ball bearing guided cutters. trend routing technology 62 trend routing technology 63 trend routing technology Router carver cutters are available in 8mm, 1/2” and 12mm shank sizes to suit most makes of plunging routers. To use the system effectively, the router must have a smooth How does it work? plunge action. A router with a minimum base Carvings are routed by the horizontal movement of the router aperture of 40mm must be used to which is guided along the varying slots in the template. The accommodate 8mm shank cutters. plunge mechanism on the router is kept released allowing the Cutters with 1/2” and 12mm shanks, router head to be guided up and down vertically as the slots require a 45mm aperture. narrow and widen. Thus the depth and width of the cut is varied to give an authentic carving effect.

Template slot A A A A

B B B B

Diagram showing rise and fall of the cutter as it travels along the slot trend routing technology 64 To Rout A Carving 1 The template frame is clamped on the work (it should be left in place until all routing operations are finished). Slots from different templates can be chosen and used in conjunction to create individual designs. 2 One template is located into the frame. (There may be up to three templates per design). 3 Starting at the widest part of each slot, the router is guided with slight This 15 minute product downward pressure with the router's video gives you the basics plunge mechanism released. Depth and on authentic carving with the Router Carver system as width of the cut is automatically well as sign-writing with the Trend Routergraph. controlled. Ref. TV/1 4 For two-way symmetrical designs, the template is then removed, inverted and Full details are shown in this leaflet. An instruction replaced. Each slot is thus used twice. manual is also available which shows the carving designs to scale. Ref. LEAF/RC 65 Other booklets available in the series:

Routing - A Guide to 30 Routing Techniques for Getting Started Tradesmen & Home Improvers This 32 page colour booklet will This ‘30 Routing Techniques’ take the beginner step by step booklet is packed with practical from setting up your router, to routing ideas and techniques for using all the cutters in the set and Tradesmen and Home Improvers. their correct application. Routing Techniques for Cutter & Collet Care Ref. BOOK/SS4 Ref. BOOK/SS3 Doll’s House Mouldings A 56 page illustrated booklet This 32 page booklet is an containing information on illustrated guide to producing dolls cutters, collets and routers. house mouldings with a router. It covers their design, correct application and maintenance. Ref. BOOK/DH1 Ref. BOOK/CCCK

TREND BOOK/PD BOOK/PD v1.0 Trend Machinery & Cutting Tools Ltd Unit 6 Odhams Trading Estate Watford Herts WD2 5TR England Literature Hotline: 0800 4 TREND (0800 487363) Fax: 01923 236879 Email: [email protected] WWW: http://www.trendm.co.uk