trend KWJ900 Kitchen Worktop Jig Instruction Manual

trend KWJ900 Kitchen Worktop Jig

INSTRUCTION MANUAL

MODEL: KWJ700/900

Definition of Surfaces on a Worktop

• Worktop Face Up
• Worktop Width
• Worktop Face Down
• Postformed edge
• Pin

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

TECHNICAL DATA

| KWJ700| KWJ900
---|---|---
Jig thickness| 12mm| 12mm
Cutter size| 12.7mm| 12.7mm
Workpiece thickness max| 45mm| 45mm
Worktop width| 250mm-700mm| 400mm-900mm
Guide bush size| 30mm| 30mm
Weight| 5.4kg| 7.7kg

The following symbols are used throughout this manual:

Refer to the instruction manual of your power tool.
Denotes risk of personal injury, loss of life or damage to the tool in case of non- observance of the instructions in this manual.
This unit must not be put into service until it has been established that the power tool to be connected to this unit is in compliance with 2006/42/EC (identified by the CE marking on the power tool) or UK Statutory Instruments 2008 No. 1597 – The Supply of Machinery (Safety) Regulation (identified by UKCA marking on the power tool).

INTENDED USE

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

SAFETY

Please read and understand the safety points in these instructions as well as you power tool instructions.

PLEASE KEEP THE INSTRUCTIONS IN A SAFE PLACE

Safety Points

1. Disconnect power tool attachment from power supply when not in use, before servicing, when making adjustments and when changing accessories such as cutters. Ensure switch is in “off” position and cutter has stopped rotating.
2. Read and understand instructions supplied with power tool, attachment and cutter.
3. Current Personal Protective Equipment (PPE) for eye, ear and respiratory protection must be worn. Keep hands, hair and clothes clear of the cutter.
4. Before each use check cutter is sharp and free from damage. Do not use if cutter is dull, broken or cracked or if any damage is noticeable or suspected. Only use tools for woodworking to EN847 safety standard. Ensure cutting tool is suitable for application.
5. The maximum speed (nmax) marked on tool or in instructions or on packaging shall not be exceeded. Where stated, the speed range should be adhered to.
6. Insert the shank into the router collet at least all the way to the marked line indicated on the shank. This ensures at least 3⁄4 of the shank length is held in collet. Ensure clamping surfaces are clean.
7. Check all fixing and fastening nuts, bolts and screws on power tool, attachment and cutting tools are correctly assembled, tight and to correct torque setting before use.
8. Ensure all visors, guards and dust extraction is fitted.
9. The direction of routing must always be opposite to the cutter’s direction of rotation.
10. Do not switch power tool on with the cutter touching the workpiece.
11. Trial cuts should be made in waste material before starting any project.
12. Repair of tools is only allowed according to tool manufacturers instructions.
13. Do not take deep cuts in one pass, take shallow passes to reduce the side load applied to the cutter.
14. User must be competent in using woodworking equipment before using our products. Dress properly, no loose clothing/jewellery, wear protective hair covering for long hair.
15. Consider working environment before using tools. Ensure working position is comfortable and component is clamped securely. Keep proper footing and balance at all times. Check work area forobstructions. Keep control of power tool at all times.
16. Please keep children and visitors away from tools and work area.
17. All tools have a residual risk so must therefore be handled with caution.
18. Only use Trend original spare parts and accessories.

If you require further safety advice, technical information, or spare parts, please call Trend Technical Support or visit www.trend-uk.com

WARNINGS

• Whenever clamps are used, ensure they do not foul the router path and that they are securely tightened.
• In order to prevent breakout of the laminate, rotation of the cutter and feed direction of the router must always be into the postform edge of worktop.
• Ensure worktop is held securely to trestles. Ensure jig is clamped securely to worktop and placed at a comfortable height.
• Best results are achieved when the centre line of the bolt corresponds to the centre line of the worktop. Clamp jig securely to worktop.
• Release plunge on router at end of each cut.
• Ensure working position is comfortable. Keep proper footing at all times.
• Please check hole size is suitable for mixer tap.
• The radius size engraved into jigs is the resulting radius using a cutter and guide bush.

ITEMS ENCLOSED – (Fig.1)

• 1 x Worktop jig
• 6 x Worktop jig pins

DESCRIPTION OF PARTS – (Fig.1)

A. Jig body
B. Postform joint slot
C. Female 90O joint pin location hole 35mm
D. Male 90O joint pin location 35mm
E. Bolt recess pin location hole
F. 150mm connecting bolt open end recess slot
G. 35mm circular hinge recess & ¾” BSP hole
H. Location hole code
I. Radius corner R100
J. Radius corner R40
K. Hob joint pin location hole (female)
L. 22.5 Mitre (hob) joint pin location hole (male)
M. Curved peninsular R400
N. 45O angle end cut
O. 65mm connection bolt sight line
P. Pin
Q. Square cut sight line
R. Feed direction arrow line
S. Worktop width pin location hole

ITEMS REQUIRED

• 1/2” plunge router
• 30mm guide bush
• 2 x Clamps
• Hand tools
• 12.7mm diameter x 50mm depth router cutter with ½” shank
• 2 x Trestles
• Sealent
• Panel connector bolts
• Wooden biscuits size No. 20

ASSEMBLY & ADJUSTMENT

Recommended Cut Depths and Clearance

Ensure router cutter tip clears underside by 3mm.

Correct Bolt Recess Depths

Types of Cuts

Roughing Cuts

Set-up for roughing cuts.

Roughing Cuts
Set-up for roughing cuts.

Setting out the Joints

When cutting a joint ensure location pins 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 Pin Identification

Up to 6 location pins are used in different holes in the jig to align the correct template aperture for the application.

F90 – Female joint, 35mm inset
M90 – Male joint, 35mm inset
M45 – Male joint, 45°/hob joint
F45 – Female joint, 45°/hob joint
B – Connector Bolt Recess

Location pins are tapered to ensure a good tight fit in hole.

OPERATION

90O Right Hand Joint – (Fig.2a-3d)

2a) Setting up for Right Hand 90O Female Joint.
2b) Routing roughing cuts x 5 for Right Hand 90O Female Joint.
2c) Routing finishing cut for Right Hand 90O Female Joint.
2d) Cutting bolt recess slots for female 90O connecting bolt.

3a) Setting up for Right Hand 90O Male Joint.
3b) Routing roughing cuts x 5 for Right Hand 90O Male Joint.
3c) Routing finishing cut for Right Hand 90O Male Joint.
3d) Cutting bolt recess slots for Male 90O connecting bolt.

90O Left Hand Joint – (Fig.4a-5d)

4a) Setting up for Left Hand 90O Female Joint.
4b) Routing roughing cuts x 6 for Left Hand 90O Female Joint.
4c) Routing finishing cut for Left Hand 90O Female Joint.
4d) Cutting bolt recess slots for Female 90O connecting bolt.
5a) Setting up for Left Hand 90O Male Joint.
5b) Routing roughing cuts x 6 for Left Hand 90O Male Joint.
5c) Routing finishing cut for Left Hand 90O Male Joint.
5d) Cutting bolt recess slots for Male 90O connecting bolt.

45O Joint (Corner Joint) – (Fig.6a-9d)

6a) Setting up for the Right Hand 45O Female Joint.
6b) Routing the Right Hand 45O Female Joint roughing cuts x 5.
6c) Routing the Right Hand 45O Female Joint finishing cut.
6d) Cutting bolt recess slots Female 45O connecting bolt.

7a) Setting up for the Right Hand 45O Male Joint.
7b) Routing the Right Hand 45O Male roughing cuts x 5.
7c) Routing the Right Hand 45O Male Joint finishing cut.
7d) Cutting bolt recess slots for Male 45O connecting bolt.
8a) Setting up for the Left Hand 45O Female Joint.
8b) Routing the Left Hand 45O Female Joint roughing cuts x 6.
8c) Routing the Left and 45O Female Joint finishing cut.
8d) Cutting bolt recess slots Female 45O connecting bolt.
9a) Setting up for the Left Hand 45O Male Joint.
9b) Routing the Left Hand 45O Male Joint roughing cuts x 6.
9c) Routing the Left Hand 45O Male Joint finishing cut.
9d) Cutting bolt recess slots for Male 45O connecting bolt.

Square End Routing of Worktops

The jig can be used to square cut the worktop using the central slot. Engraved lines on the jig correspond to the edge of the worktop. Up to 650mm wide worktops can be square cut using the central slot with the KWJ700 as a router guide and up to 850mm wide with the KWJ900. Follow the cutting instructions on previous pages to cut the worktop.

Peninsular Joint

Rout cuts 2, 3, 4 and 5 before routing the curved peninsula

Routing the Curved Peninsular

Routing 3/4” BSP Hole

Please check hole size is suitable for mixer tap.

• Mark position of hole for tap in worktop.
• Place jig in position so that hole in jig is over hole position.
• Secure the jig with clamps.
• Set the depth of cut for 8-10mm and plunge cut.
• Repeat at different depths until hole is routed.

Routing 35mm Circular Hinge Recess

• Mark the position of the hinge on the door. The centre of the holes should be roughly 100mm from the top of the door to give the required support, ensure this measurement is as accurate as possible.
• Position the jig on the door.
• Set the depth for 10mm.
• Repeat operation increasing the cut by 1mm, therefore setting the total depth for 11mm. (This should be enough clearance for most hinges. Adjust this measurement if you require holes for thicker hinge heads).

45O Angle End Cut

Corner Radius

R40mm or R100mm

Special Note:

Due to the nature of this particular cut, the corner radius will be more awkward to edge laminate.

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 Ref. 342 or C152 can be used with a portable router. The size of biscuit used should be No. 20.

Ref. BSC/20/100 (100 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.

ACCESSORIES

Please use only Trend original accessories.

Recommended Cutters

Ref. 3/83X1/2TC, 3/83DX1/2TC, 3/83DCX1/2TC, C153X1/2TC, C153DX1/2TC or RT/13X1/2TC

Sub-base Set

• Ref. UNIBASE
• To obtain a perfect accurate close fitting joint, a 30mm guide bush must be used. The guide bush must always be fitted concentric with the cutter. This can be achieved using a Universal Sub-base and 30mm outside diameter guide bush ref. GB30/A.

30mm Guide Bush

•  Ref. GB30/A

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)

Biscuit Jointer for the Router

• Ref. 342X1/2TC
• Ref. C152X1/2TC

Flat Biscuit

• Ref. BSC/20/100 (Pack of 100 biscuits)
• Ref. BSC/20/1000 (Pack of 1000 biscuits)

Clamps

• Ref. FC/200

MAINTENANCE

Please use only Trend original spare parts and accessories.
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.

Storage

• After use store jig in its packaging or it can be hung on a wall hook.
• An accessory case is available, Ref. CASE/1001.

Spares

• Ref. KWJ/PIN/4

ENVIRONMENTAL PROTECTION

Recycle raw materials instead of disposing as waste.
Packaging should be sorted for environmental-friendly recycling.
The product and its accessories at the end of their life should be sorted for environmental friendly recycling.

WARRANTY

The jig carries a manufacturer’s warranty in accordance with the conditions on our website www.trend-uk.com

TROUBLESHOOTING

concentricity of cutter with guide bush. Cutter 12.7mm diameter with 30mm diameter guide bush.
Ensure location pins touch worktop.
The back edge of the joint does not line up.| Either the end stop pin or template was in the incorrect position, or the worktop has not pushed up against the end stop pin when the joint was cut.| Check position of end stop pin and re-cut joints.
When clamped together, the joint has irregular gaps.| The guide bush has drifted away from the edge of the template whilst cutting either part of the joint, or wood chips in particle board have torn slightly.| Check with a straight edge which part of the joint is uneven and re-cut (this can only be done on the male cut), ensuring that the guide bush
is kept against the template by machining from left to right. Use abrasive paper to remove torn wood chips.
Chipped laminate.| Can be caused by a blunt cutter or removing too much material at one pass or exiting out of postform edge.| Always use sharp cutters and when cutting through the laminate cut
3-4mm of material. Maintain correct feed direction to ensure cutter enters postform edge.
Jig slipping on material.| Clamps not secure or too deep a cut being made or cutter is blunt.| Check clamps for wear. Clamp securely, take shallow passes, use a sharp cutter.
Cut joints not square.| Router has tilted or operator has leaned heavily on router causing jig flex.| Ensure jig is supported and do not push hard on router taking shallow passes. Ensure weight of router is on supported part of jig and that the router is upright.
Assembled joint not flush or bowed.| Worktop different thickness or worktop not flat (cupped).| Ensure worktop is same thickness and flat.

Trend Tool Technology Ltd.
Watford, WD24 7TR, England
Tel: 0044(0)1923 249911
technical@trendm.co.uk
www.trend-uk.com
EU Importer:
Trend Tool Technology Ltd.
3rd Floor, Kilmore House, Park Lane,
Spencer Dock, Dublin 1, Ireland

Trend Tool Technology Ltd. 2020, 2021, 2023.
® All trademarks acknowledged E&OE

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 Tool Technology Ltd. cannot be held liable for any material rendered unusable, or for any for of consequential loss. E&OE.

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