TREND LOCK JIG User manual
LOCK JIG
LOCK JIG
-2-
SAFETY
Observe the safety regulations in the
instruction manual of the Power Tool to
be used or connected to this
attachment. Also observe any
applicable additional safety rules. Read
the following safety instructions before
attempting to operate this product.
PLEASE KEEP THESE
INSTRUCTIONS IN A SAFE
PLACE.
The attention of UK users is drawn to
The Provision and Use of Work
Equipment Regulations 1998, and any
subsequent amendments.
General
■Disconnect power tool, when not in
use. Before servicing and when
changing accessories such as
cutters. Disconnect power tool and
attachment from power supply.
Ensure the machine is switched off
before plugging tool in or
connecting to a power supply.
■Always mount the power tool,
accessory or attachment in
conformity with the present
instructions.
■Keep children and visitors away. Do
not let children or visitors touch the
tool, accessory or attachment.
Keep children and visitors away
from work area.
■Make the workshop child proof with
padlock and master switch.
■Dress properly. Do not wear loose
clothing or jewellery, they can be
caught in moving parts. Rubber
gloves and non-skid footwear is
recommended when working
outdoors. Wear protective hair
covering to contain long hair.
■Consider working environment. Do
not use the product in the rain or in
a damp environment. Keep work
area well lit. Do not use power tools
near gasoline or flammable liquids.
Keep workshop at a comfortable
temperature so your hands are not
cold.
■The accessory or attachment must
be kept level and stable at all
times.
■Keep work area clean. Cluttered
workshops and benches can cause
injuries
■Use the attachment with the power
tools and accessories specified in
this manual only. Do not force the
tool or attachment to do a job for
which it is not designed.
■Secure idle tools. When not in use,
tools should be stored in a dry and
high or locked up place, out of
reach of children.
■For best control and safety use
both hands on the power tool and
attachment. Keep both hands away
from cutting area. Always wait for
the spindle and cutter to stop
rotating before making any
adjustments.
■Always keep guards in place and in
good working order.
■Remove any nails, staples and
other metal parts from the
workpiece.
■Maintain tools and cutters with
care. Keep cutters sharp and clean
for better and safer performance.
Do not use damaged cutters.
Follow instructions for lubricating
and changing accessories. Keep
handles dry, clean and free from oil
and grease.
■Maintain accessories. Do not use
damaged accessories. Only use
accessories recommended by the
manufacturer.
■Check damaged parts. Before
operation inspect the attachment,
the power tool, the cable, extension
cable and the plug carefully for
signs of damage. Check for
alignment of moving parts, binding,
breakage, mounting and any other
conditions that may effect its
operation. Have any damage
repaired by an Authorised Service
Agent before using the tool or
accessory.
■Do not use tool if switch does not
turn it on or off. Have defective
switches replaced by an Authorised
Service Agent.
■Don't over reach. Keep proper
footing and balance at all times.
■Don’t abuse the cable. Never carry
power tool or accessory by cord or
pull it to disconnect from the
socket. Keep cord from heat, oil
and sharp edges. Always trail the
power cord away from the work
area.
■Connect dust extraction equipment.
If devices are provided for the
connection of dust extraction and
collection facilities, ensure these
are connected and properly used.
■Check all fixing and fastening nuts,
bolts and screws before use to
ensure they are tight and secure.
Periodically check when machining
over long periods.
■Stay alert. Watch what you are
doing. Use common sense. Do not
operate tools when you are tired,
under the influence of drugs or
alcohol.
■Personal Protective Equipment
(PPE). All PPE must meet current
UK and EU legislation.
■Do not leave tools running
unattended. Do not leave tool until
it comes to a complete stop.
■Always clamp workpiece being
machined securely.
Routing Safety
■Disconnect router power tool.
When not in use, before servicing
and when changing accessories
such as cutters, disconnect router
and attachment from power supply.
■Ensure router cutter has stopped
rotating before changing it. Never
use the spindle lock as a brake.
■Remove adjusting keys and
spanners. Form the habit of
checking to see that keys and
adjusting spanners are removed
from the router tool, cutter and
attachment before turning router
on. Make sure cutter can rotate
freely.
■Check all ball bearing and blade
fixing screws before use to ensure
they are tight and secure.
Periodically check when machining
over long periods.
■When using a template guide bush
ensure it cannot come into contact
with collet and nut.
■Noise. Take appropriate measures
for the protection of hearing if the
sound pressure of 85dB(A) is
exceeded. Routing sound pressure
may exceed 85dB(A), so ear
protection must be worn.
■Eye protection. Wear safety
goggles, spectacles or visors to
protect the eyes from ejected
waster particles.
LOCK JIG
-3-
■Respiratory protection. Wear a face
or dust mask, or powered
respirator. Dust masks/filters should
be changed regularly.
■Do not switch router on with the
cutter touching the workpiece.
■The direction of routing must
always be opposite to the cutter's
direction of rotation.
■After work, release the router
plunge and allow spindle to stop
rotating before putting machine
down.
■Check before cutting that there are
no obstructions in the path of the
router. When cutting through the full
thickness of the workpiece, ensure
there are no obstacles beneath
workpiece, and that a sacrificial
work surface is used.
Additional Safety Rules For
Router Cutters
■Cutting tools are sharp. Care
should be taken when handling
them.
■Always use cutters with a shank
diameter corresponding to the size
of the collet installed in your tool.
■Always run router cutters at the
spindle speed recommended and
marked accordingly. Ensure cutter
has reached correct speed before
entering workpiece. Recommended
speeds can be found on the
packaging, in cutter instructions or
in the Trend Routing Catalogue.
■Always use router cutters in a
router. Router cutters must not be
used in a drill. Drill and boring bits
must not be used in a router.
Router cutters must only be used
for the material cutting application
for which they are designed. Do not
use on metal or masonary.
■Never use cutters with a diameter
exceeding the maximum diameter
indicated in the technical data of
the powertool or attachment used.
■Do not drop cutters or knock them
against hard objects. Do not use
cutters that are damaged.
■Cutters should be kept clean. Resin
build up should be removed at
regular intervals with Resin
Cleaner®. The use of a dry
lubricant (Trendicote®PTFE) will
act as a preventative. Do not use
PTFE spray on plastic parts.
■Cutter shanks should be inserted
into the collet to the mark line on
the shank. This ensures that at
least
3
⁄
4
of the shank length is held
in the collet. Do not over-tighten the
collet nut as this will score the
shank and create a weakness and
fracture point.
■Observe the correct assembly
instructions in the router instruction
manual for fitting the collet and nut.
Observe the router power tool
manual instructions on fitting
cutters correctly.
■It is advisable to periodically check
the collet and collet nut. A worn,
distorted or damaged collet can
cause vibration and damage the
shank, and should be replaced.
Worn collet nuts should be
replaced.
■Do not take deep cuts in one pass;
take several shallow or light passes
to reduce the side load applied to
the cutter. Too deep a cut in one
pass can stall the router.
■Very small diameter cutters must
be handled and used with care.
■Always return cutter to its
packaging after use.
■Should you experience excessive
vibration during use stop
immediately. Have the eccentricity
of the router, router cutter and
clamping system checked.
■All fastening screws and nuts
should be tightened using the
appropiate spanner or key in
accordance with the manufacturers
instructions.
Using Routers In A Fixed
Position
■After work, release the router
plunge to protect the cutter.
■Always use a push-stick or push-
block for last 300mm of the cut.
■Whenever possible use a work
holding device or jig to secure
component being machined.
■Ensure attachment is securely fitted
to the workbench, with table
surface at approximately hip height.
■Ensure a No-Volt Release Switch is
fixed to or adjacent to the
attachment and that it is used
correctly.
■Check the direction of the
workpiece is always opposite to the
cutter's direction of rotation.
■Do not use awkward or
uncomfortable hand positions.
■Do not reach underneath table or
put your hands or fingers at any
time in the cutting path while tool is
connected to a power supply.
Useful Advice When Routing
■Judge your feed rate by the sound
of the motor. Feed the router at a
constant feed rate. Too slow a feed
rate will result in burning.
■Take many light passes rather than
one deep cut to reduce the side
load applied to both router and
router cutter.
■Trial cuts should be made on waste
material before starting any project.
■When using some attachments
including a router table or dovetail
jig, the use of a fine height adjuster
is highly recommended.
■When using a template guide bush,
ensure there is sufficient clearance
between cutter tip and inside each
of bush. Ensure cutter and guide
bush are concentric.
Router Cutter Maintenance
■Composite cutting tools (brazed tip)
must be maintained by a competent
person i.e. a person of training and
experience, who has knowledge of
the design requirements and
understands the levels of safety to
be achieved.
■The design of composite tools must
not be changed in the process of
maintenance.
■Replacement parts must meet
Trend specification.
■Tolerances which ensure correct
clamping by the collet shall be
maintained.
■When re-grinding the tool, care
must be taken not to cause
weakening of the body or the
connection between the cutting
edge and the body.
Version 4.0 08/2003
LOCK JIG
-4-
LOCK JIG
LOCK JIG
G
Mortise x4
Face-plate x12
ITEMS ENCLOSED
x1
x1
x2
x3
x3
x6
x2
x2
x1
x1
x1
x1
LOCK JIG
-5-
ASSEMBLY & DESCRIPTION OF PARTS
Assembly Diagram
Use the drawing below as a guide to
assemble the jig.
1
2
6
3
4
5
7
8
9
12
13
10
11
14
1. Jig body
2. Adjustable lever
fixing stud
3. Clamp bar
4. Adjustable lever washer
5. Adjustable lever M8
6. Spacer finger fixing stud
7. Spacer finger
8. Spring washer
9. Mini knob M5
10. Guide bush collar 16mm to 30mm
11. Collar park
12. Mortise template
13. Face plate template
14. Clamping knob with pad
LOCK JIG
-6-
Assembly Instructions
■Remove the transit washer and nut from the
middle adjusting lever fixing stud (2) on the jig
body (1). Fit the three washers (4), and fit the
three adjustable levers (5). To tighten the
adjustable levers, lift the lever up and rotate
the knurled part whilst keeping the lever body
stationary. When hand-tight, release the
ratchet and tighten using the lever.
■Remove the protective film from the spacer
fingers (7) then place three spacer fingers
onto the spacer finger fixing stud (6). See
Setting the Spacers (right) for adjustment. Fit
the spring washer (8) and the mini knob (9)
onto the spacer finger fixing stud (6) and
tighten. Repeat procedure for other
assembly.
Special Note:
The Lock Jig can be used to cut the face-plate
recess in the edge of doors whilst it is hung.
The mortise should NOT be routed
when the door is hung.
Always ensure that the door is firmly
secured if routing the face-plate on a
hung door, so there is no possibility of
the door swinging open or shut.
Setting the Spacer Fingers
■Spacers need to be used to ensure the spigot
of the guide bush will not contact the door
edge when routing.
■Three spacers per end of the jig are provided
and can be parked when not in use or rotated
in when required.
■Clamp the jig to the door and place the router
fitted with guide bush into the aperture. If the
guide bush does not contact the door edge,
then no spacers need to be used.
■If the guide bush contacts the door edge,
calculate how many spacers are required.
Each spacer is 2mm thick.
■Undo each of the two M5 knobs and lift off the
spacers. Rotate the required number of
spacers by 90° so they line up across the jig
and replace all unused spacers. Tighten the
M5 knobs.
No Spacer
Fingers used.
Face-plate only
One Spacer
Finger used.
Face-plate and mortise
LOCK JIG
-7-
12mm
Choice of Set-ups
Option 1
Plunge
Length
++
Heavy duty router with
1
⁄
2
” collet e.g. T9 Router Router Cutter
Ref. TR37X1/2TC
overall length 115mm
OR USE
Router Cutter
Ref. TR37MX1/2TC
overall length 100mm
with the following
routers:
RYOBI R600, R600(N)
RE601
Makita 3612(C)
Skil 1875U1
30mm Guide
Bush Ref. GB30
See page 8 if a
suitable guide bush
is not available
for your router.
Suitable Plunge Router:
Your router should have following
plunge length:
- For 2” deep locks at least 54mm.
- For 2
1
⁄
2
" deep locks at least
66mm.
- Auger bit and drill required for 3”
deep locks for all routers.
Due to the extra long length of this
cutter, extra care should be taken to
avoid damage. The cutter should be
used to plunge rout a series of
overlapping holes. See page 13.
Fit sufficient length of the shank into
the collet. Ideally at maximum
plunge, only as much of the cutter
should protrude below the base as is
required to reach the depth of the
mortise.
Do not attempt to increase the depth
of cut by having less than the
optimum length of the cutter’s shank
inserted in the collet of your router.
One Spacer required
with T9 router.
LOCK JIG
-8-
Three Spacers required
with T5 router.
Option 3
Using the Lock Jig with the Trend Hinge Jig
■If the Lock Jig is to be used in conjunction with the Trend Hinge
Jig, use the Guide Bush Collar to bush out the 16mm guide bush
(supplied with the Hinge Jig) to 30mm diameter. This makes it
unnecessary to change guide bushes between operations.
Guide Bush Collar
Ref. GB/COLL/1630
Supplied with Lock Jig
12mm
++
Medium duty router with
1
⁄
4
” collet e.g. T5 Router Router Cutter
Ref. TR12X1/4TC
or 3/8LX1/4TC
16mm Guide
Bush Ref.
GB160
Supplied with
Hinge Jig
Deepening of
mortise with auger
bit and drill will be
required.
No Spacers required
with T5 router.
Option 2
12mm
Deepening of
mortise with auger
bit and drill will be
required.
++
Medium duty router with
1
⁄
4
” collet e.g. T5 Router 30mm Guide Bush
Ref. GB30
Router Cutter
Ref. TR12X1/4TC
overall length 70mm
OR USE
Router Cutter
Ref. 3/8LX1/4TC
overall length 66mm
LOCK JIG
-9-
Guide Bush and Sub-base Sets
■Should the correct guide bush not be
available to suit your router’s base, you will
need to use the Trend UNIBASE in
conjunction with a 30mm guide bush, Ref.
GB30 or 16mm guide bush Ref. GB160.
■The UNIBASE has a central recess to allow
fitting of all Trend guide bushes to most
makes of routers.
■The UNIBASE contains a line-up bush, two
line-up pins and all the necessary screws.
The line-up pins and bush ensure exact
alignment of sub-base with the router spindle
when fitted with the relevant collet.
60mm
50mm
UNIBASE comprises the following: The UNIBASE fits the following Router
Models
Atlas Copco OFSE2000
Bosch GOF1300ACE, 1600A, 1700ACE
Casals FT2000VCE
CMT CMT1E
DeWalt DW624, 625EK, 629
Draper R1900V
Elu MOF131, 177(E)
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
UNIBASE
Sub-base
170mm Ø
x 8mm
Line-up pin
shank
1
⁄
4
” +
1
⁄
2
”
Line-up pin
8mm +
12mm shank
16mm
Line-up guide bush
1/2" 12mm
1/4" 8mm
LOCK JIG
-10-
Fitting the Guide Bush
Fitting Guide Bush to T9 Router
■If using the Trend T9 Router, fit the 30mm
guide bush supplied with the router. Make
sure the bush is correctly centred using the
line-up pin.
If there is any doubt about the
concentricity of cutter relevant to the
guide bush, then a sub-base should
be used in order to ensure an
accurate fit of face-plate.
Ensure guide bush collar is fitted fully
onto the guide bush with chamfer
facing the jig.
Fitting Guide Bush to T5 Router
■If using the Trend T5 Router, purchase and fit
a GB30.
■If using the Hinge Jig, fit the GB160 supplied
with the Hinge Jig. By using the Guide Bush
Collar supplied with the Lock Jig, the same
router set-up can be used by simply fitting the
collar in between the hinge and lock
operations.
■The guide bush collar can be stored on the
spigot fixed to the outside of the clamp bar
when not in use.
Ref. GB160
Ref. GB30
Ref. GB30
Guide bush
collar
Make sure guide bush
collar is fitted with
chamfered edge facing
the jig when parked.
This will make it easier
to remove.
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