Trend Dovetail Jiginst - dj300

DJ300 v8.
0 English 30/10/06 11:47 am Page 1
DJ300
DJ300 v8.0 English 30/10/06 11:47 am Page 1
DJ300
Dear Customer TECHNICAL DATA

Thank you for purchasing this Trend product, we
hope you enjoy many years of creative and Dovetail size 12.7mm
productive use. Max workpiece 300mm
Please remember to return your guarantee card Workpiece 11-25mm
within 28 days of purchase. Guide bush size 15.7mm
Weight 5kg
Contents Max. router base dia. 180mm
TECHNICAL DATA ______________________1
SAFETY _____________________________2-3
ITEMS ENCLOSED/ The following symbols are used throughout this
manual:
DESCRIPTION OF PARTS________________4
ASSEMBLY
Denotes risk of personal injury, loss
– Diagram _____________________________6 of life or damage to the tool in case
– Assembly Instructions __________________7 of non-observance of the
– Template Specification ______________8 & 9 instructions in this manual.
– Mounting Instructions __________________10
– Setting-up the Router__________________11 Refer to the instruction manual of
your power tool.
TIMBER PREPARATION ________________12
– Timber Widths _______________________13 This unit must not be put into service until it has
– Making a Setting Block ________________13 been established that the power tool to be
OPERATION connected to this unit is in compliance with
– Setting-up for Dovetailing __________14 & 15 98/37/EC (identified by the CE marking on the
– Routing the Joint _____________________16 power tool).
REBATED DOVETAILS
– Drawer Front Preparation ______________17
– Routing the Drawer Front ______________17
– Routing the Side _____________________19
COMB JOINTING
– Timber Preparation ___________________20
– Setting-up the Jig _____________________21
– Timber Widths _______________________21
– Routing the Joint _____________________22
SPARE PARTS
– Spare Parts List ______________________23
– Spare Parts Diagram______________24 & 25
TROUBLE SHOOTING __________________26
If you require further technical

information or spare parts, please call
our technical support department on
01923 224681.
-1-
DJ300
SAFETY I Use the attachment with the power I Connect dust extraction equipment.
tools and accessories specified in If devices are provided for the
this manual only. Do not force the connection of dust extraction and
Observe the safety regulations in the tool or attachment to do a job for collection facilities, ensure these
instruction manual of the Power Tool to which it is not designed. are connected and properly used.
be used or connected to this
attachment. Also observe any I Secure idle tools. When not in use, I Check all fixing and fastening nuts,
applicable additional safety rules. Read tools should be stored in a dry and bolts and screws before use to
the following safety instructions before high or locked up place, out of ensure they are tight and secure.
attempting to operate this product. reach of children. Periodically check when machining
over long periods.
PLEASE KEEP THESE I For best control and safety use
INSTRUCTIONS IN A SAFE both hands on the power tool and I Stay alert. Watch what you are
PLACE. attachment. Keep both hands away doing. Use common sense. Do not
from cutting area. Always wait for operate tools when you are tired,
The attention of UK users is drawn to the spindle and cutter to stop under the influence of drugs or
The Provision and Use of Work rotating before making any alcohol.
Equipment Regulations 1998, and any adjustments.
subsequent amendments. I Personal Protective Equipment
I Always keep guards in place and in (PPE). All PPE must meet current
General good working order. UK and EU legislation.
I Disconnect power tool, when not in I Remove any nails, staples and I Do not leave tools running
use. Before servicing and when other metal parts from the unattended. Do not leave tool until
changing accessories such as workpiece. it comes to a complete stop.
cutters. Disconnect power tool and
attachment from power supply. I Maintain tools and cutters with I Always clamp workpiece being
Ensure the machine is switched off care. Keep cutters sharp and clean machined securely.
before plugging tool in or for better and safer performance.
connecting to a power supply. Do not use damaged cutters. I Only use cutting tools for
Follow instructions for lubricating woodworking that meet EN847-1/2
I Always mount the power tool, and changing accessories. Keep safety standards, and any
accessory or attachment in handles dry, clean and free from oil subsequent amendments.
conformity with the present and grease.
instructions. Routing Safety
I Maintain accessories. Do not use
I Keep children and visitors away. Do damaged accessories. Only use I Disconnect router power tool.
not let children or visitors touch the accessories recommended by the When not in use, before servicing
tool, accessory or attachment. manufacturer. and when changing accessories
Keep children and visitors away such as cutters, disconnect router
from work area. I Check damaged parts. Before and attachment from power supply.
operation inspect the attachment,
I Make the workshop child proof with the power tool, the cable, extension I Ensure router cutter has stopped
padlock and master switch. cable and the plug carefully for rotating before changing it. Never
signs of damage. Check for use the spindle lock as a brake.
I Dress properly. Do not wear loose alignment of moving parts, binding,
clothing or jewellery, they can be breakage, mounting and any other I Remove adjusting keys and
caught in moving parts. Rubber conditions that may effect its spanners. Form the habit of
gloves and non-skid footwear is operation. Have any damage checking to see that keys and
recommended when working repaired by an Authorised Service adjusting spanners are removed
outdoors. Wear protective hair Agent before using the tool or from the router tool, cutter and
covering to contain long hair. accessory. attachment before turning router
on. Make sure cutter can rotate
I Consider working environment. Do I Do not use tool if switch does not freely.
not use the product in the rain or in turn it on or off. Have defective
a damp environment. Keep work switches replaced by an Authorised I Check all ball bearing and blade
area well lit. Do not use power tools Service Agent. fixing screws before use to ensure
near gasoline or flammable liquids. they are tight and secure.
Keep workshop at a comfortable I Don't over reach. Keep proper Periodically check when machining
temperature so your hands are not footing and balance at all times. over long periods.
cold.
I Don’t abuse the cable. Never carry I When using a template guide bush
I The accessory or attachment must power tool or accessory by cord or ensure it cannot come into contact
be kept level and stable at all pull it to disconnect from the with collet and nut.
times. socket. Keep cord from heat, oil
and sharp edges. Always trail the I Noise. Take appropriate measures
I Keep work area clean. Cluttered power cord away from the work for the protection of hearing if the
workshops and benches can cause area. sound pressure of 85dB(A) is
injuries exceeded. Routing sound pressure
may exceed 85dB(A), so ear
-2-
protection must be worn. regular intervals with Resin I Ensure a No-Volt Release Switch is
Cleaner®. The use of a dry fixed to or adjacent to the
I Eye protection. Wear safety lubricant (Trendicote® PTFE) will attachment and that it is used
goggles, spectacles or visors to act as a preventative. Do not use correctly.
protect the eyes from ejected PTFE spray on plastic parts.
waster particles. I Check the direction of the
I Respiratory protection. Wear a face I Cutter shanks should be inserted workpiece is always opposite to the
or dust mask, or powered into the collet to the mark line on cutter's direction of rotation.
respirator. Dust masks/filters should the shank. This ensures that at
be changed regularly. least 3⁄4 of the shank length is held I Do not use awkward or
in the collet. Do not over-tighten the uncomfortable hand positions.
I Do not switch router on with the collet nut as this will score the I Do not reach underneath table or
cutter touching the workpiece. shank and create a weakness and put your hands or fingers at any
fracture point. time in the cutting path while tool is
I The direction of routing must connected to a power supply.
always be opposite to the cutter's I Observe the correct assembly
direction of rotation. instructions in the router instruction Useful Advice When Routing
manual for fitting the collet and nut.
I After work, release the router Observe the router power tool I Judge your feed rate by the sound
plunge and allow spindle to stop manual instructions on fitting of the motor. Feed the router at a
rotating before putting machine cutters correctly. constant feed rate. Too slow a feed
down. rate will result in burning.
I It is advisable to periodically check
I Check before cutting that there are the collet and collet nut. A worn, I Take many light passes rather than
no obstructions in the path of the distorted or damaged collet can one deep cut to reduce the side
router. When cutting through the full cause vibration and damage the load applied to both router and
thickness of the workpiece, ensure shank, and should be replaced. router cutter.
there are no obstacles beneath Worn collet nuts should be
workpiece, and that a sacrificial replaced. I Trial cuts should be made on waste
work surface is used. material before starting any project.
I Do not take deep cuts in one pass;
Additional Safety Rules For take several shallow or light passes I When using some attachments
Router Cutters to reduce the side load applied to including a router table or dovetail
the cutter. Too deep a cut in one jig, the use of a fine height adjuster
I Cutting tools are sharp. Care pass can stall the router. is highly recommended.
should be taken when handling
them. I Very small diameter cutters must I When using a template guide bush,
be handled and used with care. ensure there is sufficient clearance
I Always use cutters with a shank between cutter tip and inside each
diameter corresponding to the size I Always return cutter to its of bush. Ensure cutter and guide
of the collet installed in your tool. packaging after use. bush are concentric.
I Always run router cutters at the I Should you experience excessive Router Cutter Maintenance
spindle speed recommended and vibration during use stop
marked accordingly. Ensure cutter immediately. Have the eccentricity I Composite cutting tools (brazed tip)
has reached correct speed before of the router, router cutter and must be maintained by a competent
entering workpiece. Recommended clamping system checked. person i.e. a person of training and
speeds can be found on the experience, who has knowledge of
packaging, in cutter instructions or I All fastening screws and nuts the design requirements and
in the Trend Routing Catalogue. should be tightened using the understands the levels of safety to
appropiate spanner or key in be achieved.
I Always use router cutters in a accordance with the manufacturers
router. Router cutters must not be instructions. I The design of composite tools must
used in a drill. Drill and boring bits not be changed in the process of
must not be used in a router. Using Routers In A Fixed maintenance.
Router cutters must only be used Position
for the material cutting application I Replacement parts must meet
for which they are designed. Do not I After work, release the router Trend specification.
use on metal or masonary. plunge to protect the cutter.
I Tolerances which ensure correct
I Never use cutters with a diameter I Always use a push-stick or push- clamping by the collet shall be
exceeding the maximum diameter block for last 300mm of the cut. maintained.
indicated in the technical data of
the powertool or attachment used. I Whenever possible use a work I When re-grinding the tool, care
holding device or jig to secure must be taken not to cause
I Do not drop cutters or knock them component being machined. weakening of the body or the
against hard objects. Do not use connection between the cutting
cutters that are damaged. I Ensure attachment is securely fitted edge and the body.
to the workbench, with table
I Cutters should be kept clean. Resin surface at approximately hip height.
build up should be removed at
-3-
DJ300
ITEMS ENCLOSED
x4
x1 x4
x1
x1
x2
x1
x1
x1 x1
x4
x4 x1
x2
x4
x2
x6
x2
x2
x1
DJ300
x1
x4 x2
x1
x2
GUARANTEE
00
J3
D
x1 x1
x2 DJ300
x1
x4
-4-
DJ300
1
ASSEMBLY & DESCRIPTION OF 2
PARTS 5
Using the drawing below as a guide to assemble

the jig.
8
4
7
20
18
21
19
20
19 13
13
20 18
16
18 13
13
13
or 19 16
10 20
18 21
11 or
20
12
15 21 18 20 17 14 5 3 2 1
1. Clamp knob female 12. Edge guide washer

2. Nylon spacer 13. Clamp bar set bolt UNC1/4” - 20 x 13/4” (long)
3. Clamping bar - short 14. Knurled brass thumb screw
4. Clamping bar - long 15. Edge guide fastening slot
5. Spring 16. Jig body
6. Template spring pin stop 17. Lock nut UNC1/4” - 20
7. 1/2” (12.7mm) dovetail template 18. Embossed slot for bar set bolt (front slots
8. Template bracket screws hidden from view on diagram above)
9. Template bracket 19. Template set bolt UNC1/4” - 20 x 11/2” (short)
10. Dovetail edge guide 20. Half nut UNC1/4” - 20
11. Edge guide pan head screws 21. Embossed slot for template set bolt
-5-
DJ300
Setting-up the Router I Fit the 1/2” (12.7mm) dovetail cutter keeping
3/4 of the shank length in the collet.
I Fit the guide bush to the base of the router.
Adjust the height of the cutter so that it
protrudes approximately 17mm from the base
of the router for 1/2” (12.7mm) dovetails and
11mm for 1/4” (6.35mm) dovetails. After a trial
joint, slight adjustment may be required to
ensure a well fitting joint. As the guide bush
is recessed into the base of the router, these
measurements should be taken from the
router base not from the guide bush.
I Fit a fine height adjuster if available, as this

will make it easier to adjust the height
accurately. The fine height adjuster is not
required for comb jointing.
Making a Router Stand Block

I As the cutter for dovetailing should not be
retracted into the router, a useful aid is a
Router Stand Block. This is simply a piece of
scrap timber with a hole large enough to take
the protruding guide bush and dovetail cutter.
This will allow the router to stand up safely
between operations.
I Lower and lock the router carriage so that the

collet is close to the guide bush, but not
touching it.
-6-
DJ300
Mounting to Workboard
The jig should be secured to a workbench or

false work surface with the four screws supplied.
A false surface will protect the workbench and
can be quickly clamped with quick release
clamps.
Two screw locations are provided at the rear of
the jig and two on the lip at the front.
I Mark the positions of the pilot holes for the 13

screws as shown. 8m
m m
0m
I Drill 1/8” (3.2mm) pilot holes at these 19 10mm
locations.
0 mm
I Screw two of the No. 10 x 1/2” self tapping 19
screws in the work top and leave the screw
heads 2mm proud of the surface.
m
5m
17
m
5m
17
I Slide the jig over the two screw heads until

they locate.
I Use the two remaining self tapping screws to
secure the lip of the jig to the workbench or
false work surface. The jig is now secure and
ready to use.
Making a False Work Surface

I This can be constructed from 12mm to 18mm
MDF or similar material with a lip on the front m
0m
which will hook over the front of the 62
workbench. Suitable quick action clamps or
similar can then be used.
25
0m
m
40mm
-7-
DJ300
TEMPLATE SPECIFICATION
21.5mm
STANDARD
1/2” (12.7mm)
Lapped Dovetail 9.5mm (3/8”)
12.7mm (1/2”)
max.
min. 25mm
11mm
OPTIONAL ACCESSORIES
DJ300/01
1/4” (6.35mm) 11.3mm
Lapped Dovetail
4.8mm
6.3mm (1/4”)
min. max.
8mm* 12mm
* (A 6mm plywood or MDF packing piece

behind front bar is required)
25.4mm
DJ300/02
1/2” (12.7mm)
Comb Joint
max.
20mm
12.7mm (1/2”)
max.
min. 20mm
12mm
-8-
DJ300
CUTTERS REQUIRED
LAPPED L120
15.7mmØ C041A
No. 1
REBATED
12.7
mm
No. 2 104°
12.7mm
S3/31
7.74mmØ LAPPED C154
No. 3
REBATED
6.9mm
98°
No. 4
6mm
3/76
15.7mmØ COMB C021A
x1
No. 3
25mm
12.55mm
-9-
DJ300
TIMBER PREPARATION
It is important to plan your work before starting Inside
B4 B3
to save set-up time and avoid costly mistakes. Back
Both sides of the jig can be used to make the
dovetail joints. However, only clamp one pair
A4 A3
into the jig at any one time to ensure it is
clamped securely.
When joining multiple pieces for a drawer or
Inside Drawer Inside
series of drawers, label the pieces as front,
Left Bottom Right
back, sides and which face will be inside or Side Side
outside. Label the pieces so it is clear which end
mates with each other (see diagram).
The ‘A’ parts will be clamped under the front
A1 A2
clamping bar and the ‘B’ under the top clamping
bar. Even numbers will be placed against the
left-hand edge guide and the odd numbers
B1 Inside B2
against the right-hand edge guide. Front
A typical 1/2” (12.7mm) dovetail drawer has a 3/4”
(19mm ) thick front with sides made of 1/2”
material. The dovetail jig’s design requires that
you use the same stock thickness for the back
as you do for the front, if you are cutting joints
simultaneously. Your drawer fronts and backs
must be at least 5/8” (16mm) thick to fully
accommodate the length of the dovetails without
compromising strength.
B3
Before joining the actual timber components,
make a trial cut on scrap timber. This will A4 B4
A3
familiarise you with the jig and check all
dimensions used.
After all the pieces have been cut to size and
checked to ensure squareness, set them on a A1 A2
bench in the order and they will be fitted
B1 B2
together. Lay each piece down so the inside
faces up and label each piece on the inside as
shown.
The dimensions shown in these

instructions are subject to acceptable
tolerances in the manufacture of the
guide bush, template and cutter.
Therefore use the setting dimensions
as guidance only and make a trial cut
in scrap timber before starting every
project.
-10-
DJ300
Timber Widths 1/2” (12.7mm) Dovetail Template

I Any width of timber up to 300mm wide can be (21.5 mm pitch with 3mm offset line)
dovetail jointed. To obtain a symmetrical joint No. of whole tails
1 2 3 4 5 6 7 8 9...
with full tails and pins at each end, see the
21.5 43 64.5 86 107.5 129 150.5 172 193.5
chart on the right for the recommended widths
Optimum width of timber in mm
of timber. ie Pitch x No. of tails = Width (when 3mm offset line used).
I The edge guides have a built in offset to
produce exact fitting dovetail joints. Their 1/4” (6.35mm) Dovetail Template
position is adjustable to enable a symmetrical (11.3 mm pitch with 2mm offset line)
joint to be obtained with timber widths that are No. of whole tails
not ideal. Their position can be simply be 1 2 3 4 5 6 7 8 9
judged by eye. 11.3 22.6 33.9 45.2 56.5 67.8 79.1 90.4 101.7
ie Pitch x No. of tails = Width (when 2mm offset line used).
Making a Setting Block
To eliminate unnecessary measurements being
made should you change the settings of the jig
(e.g. when using other templates or adjusting the
1/2” (12.7mm) Dovetail
jig for awkward widths of timber). One should
make a setting block which should be kept safe
and used to set up the jig to create a standard
1/2” (12.7mm) dovetail joint or optional 1/4” mm
15
(6.35mm) dovetail joint.
Make the setting block as follows:
3m
I Use timber that is uniform in thickness and m
has a square end.
I Draw a line 3mm from the left and right edge.
(2mm for 1/4” (6.35mm) dovetail template). 1/4” (6.35mm) Dovetail
This will be used to set the left and right edge
guides. mm
7.5
I Draw a line 15mm from the front edge.
(7.5mm for 1/4” (6.35mm) dovetail template).
This offset will be used to set the template 2m
m
position.
Setting-up the jig with this block is shown
overleaf.
-11-
DJ300
OPERATION
Setting-up for Dovetailing When using 1/4” (6.35mm) dovetail
Standard 1/2”
(12.7mm) template the minimum material
Lapped Dovetails (and accessory 1/4” thickness is 8mm. A 6mm packing
Lapped Dovetails) piece (plywood or MDF) behind the
front bar will be required to ensure
the clamp tightens properly.
Setting the Jig using the
Setting-up Block
I Fit the Edge Guides and leave the screw
slightly loose (1).
Fit No. 1 for 1/2” Fit No. 3 for 1/4”

(12.7mm) lapped dovetail (6.35mm) lapped dovetail
I Position a scrap piece of timber (2) under the

front clamp, slightly proud of jig surface and 3
well away from the edge guide and clamp it in
this position (3). 2
I Place the setting block under the top clamp

and butt it up to the scrap piece (1). Fit the
template onto the jig and lay it on top of the
timber (2). Tighten the knurled brass thumb 1
screw (3). Slide the setting block until the
offset line is aligned with the left hand edge of
the first slot (4). See drawings below. 5 4
3mm offset line 2mm offset line 2
3
For 1/2” (12.7mm) For 1/4” (6.35mm)
lapped dovetail lapped dovetail
Tighten the top clamps making sure the

setting block does not move (5).
-12-
DJ300
I Slacken the brass thumb screw (1). Using the 3

spanner supplied (2), adjust the position of
the lock-nuts until the back of the template
slots align with the Template Setting Line (3).
1/2” (12.7mm) Dovetail Template Optional 1/4” (6.35mm) Template
2
15mm 1
template 7.5mm
setting template
line setting
line
I Remove the template (1). Slide the edge 1

guide up to the edge of the setting block (2).
After ensuring it is square, tighten the edge
guide securely (3).
Repeat the setting procedure for the right-
hand edge guide.
I Remove the setting up block and the scrap
timber and keep it safe. The jig is now ready
to use.
3
I For each joint, clamp the two pieces of timber
under the clamps making sure both are flush
with each other and touching the edge guide.
Place even numbers against the left-hand
edge guide and the odd numbers against the
right-hand edge guide. 2
Only clamp and rout one set at one

time to ensure maximum clamping
action of the clamp bars.
Tighten up top and side clamps evenly
and tighten the template securely. Periodically check tightness of all
DO NOT OVERTIGHTEN. nuts and bolts.
B2 B1
or A4 and B4
A2 or A3 and B3 A1
-13-
DJ300
Routing the Joint

I Start up the router and make one very light
cut from right to left, machining only the front
edge. This will prevent chipping out at the
next stage.
I Now carefully rout from left to right following

the guide bush in each of the slots.
Examine each of the slots to ensure all the
material have been cleanly routed. If you
discover that there are parts of the joint that
have not been cleanly routed, without
adjusting the jig, rout the joint a second time.
Do not lift the router from the

template with the guide bush engaged
in the slots as damage to the template
will occur.
I Remove material and try the joint.
Follow the table below if the joint is not as

expected.
Dovetail joint Increase depth

too loose adjustment of cutter.
Dovetail joint Decrease depth
too tight adjustment of cutter.
Dovetail joint Move template comb
too shallow towards the jig body.
Dovetail joint Move template comb
too deep away from jig body.
Adjust the jig accordingly and re-align the two

pieces carefully in the jig and rout them again.
-14-
DJ300
REBATED LAPPED DOVETAILS

The technique for setting and routing rebated
dovetails are similar to flush lapped dovetails
except, the drawer front and side are routed
separately and the drawer front must overhang
the jig when routing to allow for the rebate.
B16A
Drawer Front Preparation 3/8"
I Prepare the drawer front with a (19mm)3/4” 11.1mm

longer and 3/4”(19mm) wider dimension than (7/16")
the drawer size required. 9.5mm
3/8” 7/16” ( 3 / 8 ")
Rout a (9.5mm) wide by (11.1mm) INSIDE
deep rebate around the inside of the drawer
front, using the rebate cutter ref. 46/39 or
C040 fitted with ball bearing ref. B16A.
I Fit the appropriate edge guides and leave
slightly loose. See below:
Fit No.2 Edge Guide

for the 1/2” (12.7mm) Rebated Dovetail Template
Fit No.4 Edge Guide

for the 1/4” (6.35mm) Rebated Dovetail Template
I Fit the template to the jig (1) & tighten brass

thumb screw (2). 1
To ensure an overhang of 3/8” (9.5mm) of the
drawer front, slide a piece of scrap timber 3/8”
(9.5mm) thick under the front clamp (3),
ensuring it is well away from the edge guide.
See (A).
2
Alternatively use a scrap piece of timber with 4
a 3/8” (9.5mm) deep rebate. See (B).
Clamp it in position (4). A B 3
-15-
DJ300
I Place the drawer front under the top clamp (1) 1 Using
3/8”(9.5mm)
and make sure it is flush with the 3/8” (9.5mm) scrap timber
timber. 3 2
Slide the drawer front until the offset line
aligns with the left edge of the first slot (2).
Clamp the timber securely (3).
Using
3/8”(9.5mm)
rebated scrap timber
Timber must be moved over by one

finger on template in order to locate
edge guide.
3mm offset line 2mm offset line
Edge Guide Setting Line Edge Guide Setting Line

for the 1/2” (12.7mm) for the 1/4” (6.35mm)
Dovetail Template Dovetail Template
I Slacken the brass thumb screw (1). Using the 2

spanner supplied (2), adjust the position of 1
the lock-nuts until the back of the template
slots align with the Template Setting Line (3).
1/2” (12.7mm) Dovetail Template
1
15mm
template
setting
line
Optional 1/4” (6.35mm) Template
7.5mm
template 3
setting
line
I Remove the template (1).

Slide the edge guide up against the drawer
front (2).
2
Tighten the edge guide securing screw (3).
Replace the template.
-16-
DJ300
Referring to the marking out of the

timber on page 10 please place even
numbers against the left-hand edge
guide and the odd numbers against
the right-hand edge guide when
routing.
Routing the Drawer Front

I Fit the correct guide bush and cutter.
Rout from right to left following the guide bush
in each of the slots.
The drawer front is now finished.
For drawer fronts with a different size of 1

3
rebate, adjust dimensions accordingly.
Routing the Side

I This again is routed separately. Slide a scrap 4
piece of timber (1), the same thickness as the
side, under the top clamp. This is to prevent
tear-out. 2
Insert the side piece (2) under the front clamp
and align it with the scrap piece (1) and the
Try-square (3).
Clamp it in this position (4).
Rout as per normal lapped dovetail (see page

14 – Routing the Joint).
I Remove the side piece and check the joint.

Use the chart on page 14 for adjusting the fit
if necessary.
Setting the depth of cut in the future

To ease setting up of the cutter height in the
future, rout a joint using the setting-up block in
the same position as a drawer front. Then use
this to accurately set the depth of cut of the
cutter in the future.
-17-
DJ300
OPTIONAL ACCESSORIES
3
1/4” (6.35mm) Lapped Dovetail Template.
(See Standard Lapped Dovetail.)
1/2” (12.55mm) Box Comb Template.
Use No.3 Edge Guides
for the Comb Template
The comb template is secured to the jig in the
same manner as the dovetail templates.
The GB157 guide bush as supplied with the
standard jig should be used together with a
12.55mm dia. straight cutter ref. 3/76 or C021A.
I Assemble the template to the template
brackets using the machine screws supplied.
I Fit the guide bush and cutter to the router.
I The comb joint is best routed in two or three
passes at increased depths. Therefore the 3
step turret stop fitted to most routers is ideal
for this purpose.
The technique for setting and routing comb joints
requires each piece to be clamped in the front
clamp and routed separately. A wider piece of
scrap is clamped under the top clamp to stop
tear-out and provide support for the router. The
scrap must be at least 1/4” (6.35mm) thicker to
ensure you do not rout into the body of jig.
When using timber over 16mm thick the nylon
spacers on the clamp knob will need to be
removed. mm t
1.6 ffse
o ine
m tm l
1.6 offsee
Timber Preparation lin
I Cut all four pieces for the box to the exact
dimensions of the final unit. Make sure that
all ends are perfectly square and exact
widths.
I Mark the centre line on both pieces of
material and mark a 1.6mm (1/16”) offset to
the left and to the right of the centre line.
I Label the piece as shown in the diagram. B1 B4
A1
A4
A3
A4
B4
B3
B1 A2 A3
B2 B3
B2
A1 A2
-18-
DJ300
1/2” (12.7mm) Comb Template

Timber Widths (25.4mm pitch with Symmetrical Sockets)
I Any width of timber up to 300mm wide No. of Sockets
can be comb jointed, however to 1 2 3 4 5 6 7 8 9...
38.1 63.5 88.9 114.3 139.7 165.1 190.5 215.9 241.3
obtain an even looking symmetrical
comb joint where there is an extra
ie (Pitch x No. of Sockets) + 12.7mm = Width.
pin/socket, the timber must be
machined to a width shown in the
chart.
I For timber that is not machined to the
recommended width, either the end
pin/sockets will need to be narrow or
an un-symmetrical comb will have to
be machined.
Symmetrical Symmetrical Non-symmetrical

Extra pin/socket Reduced End Even number
pin/socket of pins/sockets
Setting up the Jig

I Fit the edge guides marked No. 3 and leave
slightly loose.
I Fit the comb template to the jig.

Slide a packing piece which is at least 1/4”
(6.35mm) thicker than the timber for the joint,
under the top clamp, flush with the front of the
jig and well away from the edge guide.
Clamp it in position. 1
I To set the left-hand edge guide, slide the first

box side (1) under the front clamp, keeping the
top edge flush underneath the template. Align
the left-hand offset line with the edge of a
finger (2).
Clamp the piece in this position (3).
1.6mm
offset
2
-19-
DJ300
1
I Remove the template (1), slide the edge
guide up against the box side (2) held
under the front clamp. Then tighten the
edge guide securing screw (3).
I Repeat the setting up operation for the
right-hand side edge guide using the right-
hand off-set line.
3
I Ensure the packing piece supports the
whole width of the box side, otherwise
breakout could occur when routing. 3
Routing the Joint

I Set the depth of cut as follows:
3 to 6mm - one pass
6 to 12mm - two passes
12 to 18mm - three passes
The full depth of cut should be the same as
the thickness of the box side. A slightly
deeper cut can be made if finishing is
desired. However be careful not to rout into
the body of the jig.
I To ensure a correctly fitting and a mirrored
joint is obtained, place the pieces marked
‘A’ against the left hand edge guide and the
‘B’ piece against the right hand edge guide.
I Rout from left to right following each finger.
I Repeat the above steps for each box side.
I If the ends of the box sides are not flush
then adjust the 1.6mm offset accordingly.
I Check the joints by assembling them dry.
Any extra length to the fingers can be
routed down and sanded off.
-20-
DJ300
MAINTENANCE
This 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.
I Cleaning
Regularly clean the jig and remove resin
build-up on all threads.
I Lubrication
Your jig requires no additional lubrication.
RECYCLING
Jigs, accessories and packaging should be
sorted for environmentally friendly recycling.
GUARANTEE
The jig carries a manufacturers guarantee in
accordance with the conditions on the enclosed
guarantee card.
For the location of your nearest Trend Service
Agent, please call the telephone number at the
back of this manual.
-21-
DJ300
DJ300 - SPARE PARTS LIST v8.0 08/2003
No. Qty. Desc. Ref.
1 1 DJ300 Jig Body c/w Studs (< 02/2001) WP-DJ300/01
1A 1 DJ300 Jig Body Embossed (> 02/2001) WP-DJ300/01A
2 1 Front Clamping Bar - short WP-DJ300/02
3 1 Top Clamping Bar - long WP-DJ300/03
4 4 Clamp Knob Male UNC1/4” - 20 x 11/2” WP-DJ300/04
4A 4 Clamp Knob Female UNC1/4” - 20 (post 02/2001) WP-DJ300/04A
5 4 Nylon Spacer WP-DJ300/05
6 4 Spring For bar WP-DJ300/06
7 2 Knurled Brass Thumb Screw WP-DJ300/07
8 2 Lock Nut UNC1/4” - 20 WP-DJ300/08
9 4 Machine Screw 1/2” (12.7mm) Dovetail UNF10 - 32 x 3/8” Skt WP-DJ300/09
10 2 Template Bracket c/w Nut WP-DJ300/10
11 2 Edge Guide Pan Head Screws UNF10 - 32 x 3/8” Skt WP-DJ300/11
12 1 No.1 1/2” (12.7mm) Edge Guide Right WP-DJ300/12
13 1 No.1 1/2” (12.7mm) Edge Guide Left WP-DJ300/13
14 1 No.2 1/2” (12.7mm) Rebated Edge Guide Right WP-DJ300/14
15 1 No.2 1/2” (12.7mm) Rebated Edge Guide Left WP-DJ300/15
16 1 No.3 1/4” (6.35mm) Edge Guide Right WP-DJ300/16
17 1 No.3 1/4” (6.35mm) Edge Guide Left WP-DJ300/17
18 1 No.4 1/4” (6.35mm) Rebated Edge Guide Right WP-DJ300/18
19 1 No.4 1/4” (6.35mm) Rebated Edge Guide Left WP-DJ300/19
20 1 1/2” (12.7mm) Dovetail Template WP-DJ300/20
21 1 1/4” (6.35mm) Dovetail Template WP-DJ300/21
22 1 1/2” (12.7mm) Box/Comb Joint Template WP-DJ300/22
23 4 Machine Screw UNF10 - 32 x 5/16” Slot (1/4” Template) WP-DJ300/23
24 1 Hex Key 1/8” (3.2mm) A/F AK/18
25 2 Machine Screw Csk M5 X 10mm Slot WP-SCW/13
26 4 Screw Self Tapping No. 10 x 1/2” Pozi WP-SCW/105
27 1 Trend Label WP-DJ300/27
28 1 DJ300 Label WP-DJ300/28
29 - - -
30 2 Edge Guide Screw Washer 5.2mm x 9.8mm x 1.1mm WP-WASH/09
31 1 Spanner 7/16” A/F WP-SPAN/716P
32 1 Guide Bush 15.7mm Dia GB157
33 1 Guide Bush 7.74mm Dia GB774
34 2 Self Adhesive Friction Strip WP-DJ300/34
35 2 Template Spring Pin Stop 3mm x 20mm WP-DJ300/35
36 0 Clamp Knob Conversion Kit* (< 02/2001) WP-DJ300/36
36A 4 Set Bolt Hex UNC1/4” - 20 x 13/4” (> 02/2001) WP-DJ300/36A
36B 2 Set Bolt Hex UNC1/4” - 20 x 11/2” (> 02/2001) WP-DJ300/36B
37 6 Half Nut Hex UNC1/4” - 20 (> 02/2001) WP-DJ300/37
38 1 Dovetail Cutter 1/2” (12.7mm) Dia x 104° L120 or C041A
39 1 Dovetail Cutter 6.0mm Dia x 98° S31/11 or C154
40 1 Straight Cutter 12.55mm Dia x 25mm Cut 3/76 or C021A
41 1 Manual MANU/DJ300
* Converts pre 02/2001 jig to post 02/2001 version.
-22-
DJ300
DJ300 - SPARE PARTS DIAGRAMS V8.0 08/2003
4A
5
34 6
9
35
4A
5 10
3
37 8 11
9
6
20 30
37
35 7
36B
10 12
36A
37
1A 6
5
36A
4A
11
36A
30
36A 28
36B
37 34
8
27
7
6
13
2
5
32
4A
25 14
15
41
24
31
WP-DJ300/36
26 Clamp Knob
Conversion Kit 38
(Pre 02/2001)
36
4A x4
36A x2
36B x2
-23-
DJ300
V8.0 08/2003
DJ300/01
23
35
10
33
25
24
23
16
21
17
35
S31/11
10
C154
18
19 39
DJ300/02
9
10
24
9
22
10
16
17
40
3/76
18 C021A
-24-
DJ300
TROUBLE SHOOTING
I Tear out - this occurs when cutting across
the grain and can be overcome by scribing
the ends of the timber with a marking knife or
gauge at the height of the cutter.
I Dovetail joint too loose - increase depth

adjustment of cutter.
I Dovetail joint too tight - decrease depth
adjustment of cutter.
I Dovetail joint too shallow - move template
comb towards the jig body by adjusting
locking nut.
I Dovetail joint too deep - move template
comb away from body by adjusting locking
nut.
I Clamping bar will not adjust sufficiently
for 23mm plus thickness - remove nylon
spacers and refit clamping knob.
I Clamping bar will not tighten sufficiently
for 8mm thickness for 1/4” (6.35mm)
dovetails - insert a packing piece behind
clamping knob.
-IB-
Trend Machinery & Cutting Tools Ltd.

Odhams Trading Estate St Albans Road
MANU/DJ300 v8.0
Watford WD24 7TR England

Enquiries: __________________0800 487363
Technical Support: ___ 0044 (0) 1923 224681
Fax: ________________0044 (0) 1923 236879
Email:____________mailserver@trendm.co.uk
RECYCLABLE Web: ____________www.trendmachinery.co.uk
© Copyright Trend 2003. 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 form of consequential loss. E&OE

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DJ300 v8.

0 English 30/10/06 11:47 am Page 1

Dear Customer TECHNICAL DATA

If you require further technical

Using the drawing below as a guide to assemble

1. Clamp knob female 12. Edge guide washer

I Fit a fine height adjuster if available, as this

Making a Router Stand Block

I Lower and lock the router carriage so that the

The jig should be secured to a workbench or

I Mark the positions of the pilot holes for the 13

I Slide the jig over the two screw heads until

Making a False Work Surface

* (A 6mm plywood or MDF packing piece

The dimensions shown in these

Timber Widths 1/2” (12.7mm) Dovetail Template

Fit No. 1 for 1/2” Fit No. 3 for 1/4”

I Position a scrap piece of timber (2) under the

I Place the setting block under the top clamp

3mm offset line 2mm offset line 2

Tighten the top clamps making sure the

I Slacken the brass thumb screw (1). Using the 3

1/2” (12.7mm) Dovetail Template Optional 1/4” (6.35mm) Template

I Remove the template (1). Slide the edge 1

Only clamp and rout one set at one

Routing the Joint

I Now carefully rout from left to right following

Do not lift the router from the

I Remove material and try the joint.

Follow the table below if the joint is not as

Dovetail joint Increase depth

Adjust the jig accordingly and re-align the two

REBATED LAPPED DOVETAILS

Drawer Front Preparation 3/8"

I Prepare the drawer front with a (19mm)3/4” 11.1mm

Fit No.2 Edge Guide

Fit No.4 Edge Guide

I Fit the template to the jig (1) & tighten brass

Timber must be moved over by one

3mm offset line 2mm offset line

Edge Guide Setting Line Edge Guide Setting Line

I Slacken the brass thumb screw (1). Using the 2

1/2” (12.7mm) Dovetail Template

Optional 1/4” (6.35mm) Template

I Remove the template (1).

Referring to the marking out of the

Routing the Drawer Front

For drawer fronts with a different size of 1

Routing the Side

Rout as per normal lapped dovetail (see page

I Remove the side piece and check the joint.

Setting the depth of cut in the future

1/2” (12.7mm) Comb Template

Symmetrical Symmetrical Non-symmetrical

Setting up the Jig

I Fit the comb template to the jig.

I To set the left-hand edge guide, slide the first

Routing the Joint

DJ300 - SPARE PARTS DIAGRAMS V8.0 08/2003