POCKET HOLEJIG

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Dear Customer

Thank you for purchasing this Trend product, wehope you enjoy many years of creative andproductive use.

Please remember to return your guarantee cardwithin 28 days of purchase.

CONTENTS

TECHNICAL DATA _____________________1SAFETY PRECAUTIONS________________2ITEMS ENCLOSED ____________________3POCKET HOLE CONCEPT ______________3DESCRIPTION OF PARTS_______________3ASSEMBLY & ADJUSTMENT– Setting up the Jig _____________________5– Setting Pocket Hole Centres ____________5– Setting the Push-Pull Clamp ____________5– Setting the Drill Bit Depth_______________6OPERATION– Material Thickness ___________________7 – Pocket Hole Spacing __________________7– Drilling the Pocket Hole ________________8– Assembling the Joint __________________9APPLICATIONS____________________10-13ACCESSORIES ______________________14MAINTENANCE ______________________14GUARANTEE ________________________14ENVIRONMENTAL PROTECTION________14SPARE PARTS– Spare Parts Diagram _________________15– Spare Parts List _____________________16TROUBLE SHOOTING_________________16

PH/JIG

TECHNICAL DATA

Material thickness: Min. 16mmMax. 38mm

Material width: Min 38mm

Drill bit size 9.5mmHole pitch 29-63mm

The following symbols are used throughout thismanual:

Denotes risk of personal injury, loss oflife or damage to the tool in case of non-observance of the instructions in thismanual.

Denotes risk of electric shock.

Refer to the instruction manual ofyour power tool.

This unit must not be put into service until it hasbeen established that the power tool to beconnected to this unit is in compliance with98/37/EC (identified by the CE marking on the power tool).

INTENDED USE

This accessory is to be used with a drill withminimum 10mm chuck capacity to allow pockethole jointing of softwoods and hardwoods. It isideally suited for use with materials 19mm thick.

☎ If you require further safety advice,technical information or spare parts,please call our technical supportdepartment on 01923 224681.

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SAFETYWARNING:

Observe the safety regulations in theinstruction manual of the power tool to beused. Please read the followinginstructions carefully. Failure to do socould lead to serious injury. When usingelectric tools, basic safety precautions,including the following should always befollowed to reduce the risk of fire, electricshock and personal injury. Also observeany applicable additional safety rules.Read the following safety instructionsbefore attempting to operate this product.

PLEASE KEEP THESEINSTRUCTIONS IN A SAFE PLACE.

The attention of UK users is drawn to TheProvision and Use of Work EquipmentRegulations 1998, and any subsequentamendments.

Users should also read the HSE/HSCSafe Use of Woodworking MachineryApproved Code of Practice and GuidanceDocument and any amendments.

Users must be competent before usingour products.

IMPORTANT NOTE:

Residual Risk. Although the safetyinstructions and operating manuals forour tools contain extensive instructions onsafe working with power tools, everypower tool involves a certain residual riskwhich cannot be completely excluded bysafety mechanisms. Power tools musttherefore always be operated withcaution!

General1. Disconnect power tool when making

any adjustments. When not in use,before servicing and when changingaccessories such as cutters,disconnect power tool and attachmentfrom power supply. Ensure themachine is switched off beforeplugging tool in or connecting to apower supply.

2. Always mount the power tool,accessory or attachment in conformitywith the present instructions. The toolshould not be modified or used for anyapplication other than that for which itwas designed.

3. Keep children and visitors away. Donot let children or visitors touch thetool, accessory or attachment. Keepchildren and visitors away from workarea. Make the workshop child proofwith padlock and master switch.

4. Dress properly. Do not wear looseclothing or jewellry, they can becaught in moving parts. Rubbergloves and non-skid footwear isrecommended when workingoutdoors. Wear protective haircovering to contain long hair.

5. Consider working environment. Donot use the product in the rain or in adamp environment. Keep work areawell lit. Do not use power tools neargasoline or flammable liquids. Keepworkshop at a comfortabletemperature so your hands are notcold. Connect machines that are usedin the open via a residual currentdevice (RCD) with an actuationcurrent of 30 mA maximum. Use onlyextension cables that are approved foroutdoor use.

6. The accessory or attachment must bekept level and stable at all times.

7. Keep work area clean. Clutteredworkshops and benches can causeinjuries. Ensure there is sufficientroom to work safely.

8. Use the attachment with the powertools and accessories specified in thismanual only. Do not force the tool orattachment to do a job for which it isnot designed.

9. Secure idle tools. When not in use,tools should be stored in a dry andhigh or locked up place, out of reachof children.

10.For best control and safety use bothhands on the power tool andattachment. Keep both hands awayfrom cutting area. Always wait for thespindle and cutter to stop rotatingbefore making any adjustments.

11. Always keep guards in place and ingood working order.

12.Remove any nails, staples and othermetal parts from the workpiece.

13.Maintain tools and cutters with care.Keep cutters sharp and clean forbetter and safer performance. Do notuse damaged cutters. Followinstructions for lubricating andchanging accessories. Keep handlesdry, clean and free from oil andgrease.

14.Maintain accessories. Do not usedamaged accessories. Only useaccessories recommended by themanufacturer.

15.Check damaged parts. Beforeoperation inspect the attachment, thepower tool, the cable, extension cableand the plug carefully for signs ofdamage. Check for alignment ofmoving parts, binding, breakage,mounting and any other conditionsthat may effect its operation. Haveany damage repaired by anAuthorised Service Agent before usingthe tool or accessory. Protect toolsfrom impact and shock.

16.Do not use tool if switch does not turnit on or off. Have defective switchesreplaced by an Authorised ServiceAgent.

17.Don't over reach. Keep properfooting and balance at all times. Donot use awkward or uncomfortablehand positions.

18.Don’t abuse the cable. Never carrypower tool or accessory by cord orpull it to disconnect from the socket.Keep cord from heat, oil and sharpedges. Always trail the power cordaway from the work area.

19.Connect dust extraction equipment. Ifdevices are provided for theconnection of dust extraction andcollection facilities, ensure these areconnected and properly used.

20.Check all fixing and fastening nuts,bolts and screws on power tool,attachment and cutting tools beforeuse to ensure they are tight andsecure. Periodically check whenmachining over long periods.

21.Stay alert. Watch what you aredoing. Use common sense. Do notoperate tools when you are tired,under the influence of drugs oralcohol.

22.Personal Protective Equipment(PPE). All PPE must meet currentUK and EU legislation.

23.Do not leave tools runningunattended. Do not leave tool until itcomes to a complete stop.

24.Always clamp workpiece beingmachined securely.

25.Only use cutting tools forwoodworking that meet EN847-1/2safety standards, and anysubsequent amendments.

26.Vibration levels. Hand held powertools produce different vibrationlevels. You should always refer to thespecifications and relevant Health &Safety Guide.

Version 6.0 05/2005 PT1

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DESCRIPTION OF PARTS

A Pocket hole jig body

B Guide columns with solid hardened bushes

C Solid bush drill guide hole

D Guide column equidistant scale

E Guide column adjustment screw

F Guide column adjustment screw hex key4mm A/F

G Push-pull toggle clamp

H Push-pull toggle clamp handle

I Clamping pad

J Adjustable clamping pad stud

K Adjustable clamping pad lock nut

L Push-pull securing machine screws

M Push-pull securing screw hex key 3mm A/F

N Bench fixing holes

O Bench fixing screws No. 8 x 25mm

P Stepped drill

Q Stepped drill depth collar

R Depth collar hex key 2.5mm A/F

S Square drive self-tapping screw No. 7 x 30mm

T Short square drive screwdriver bit No. 2 x75mm for self-tapping screws

U Long square drive screwdriver bit No. 2 x150mm long for self-tapping screws

V Face clamp

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ITEMS ENCLOSED

1 x Pocket Hole Jig

1 x Stepped drill 9.5mm (3/8") diameter x150mm long HSS

1 x Depth collar for stepped drill

1 x Square drive screwdriver bit No. 2 x 75mm long

1 x Square drive screwdriver bit No. 2 x 150mm long

100 x Self-tapping square head screws No.7 x 30mm

1 x Hex key 4mm A/F

1 x Hex Key 3mm A/F

1 x Hex Key 2.5mm A/F

1 x Face clamp 152mm long x 42mm throat x42mm opening

3 x Particle board screw No. 8 x 25mm Pozi

1 x Manual

1 x Guarantee registration card

PH/JIG

POCKET HOLE CONCEPT

A pocket hole concept involves placing onepiece of the material to be joined in the jig andboring two counter-bored holes with a specialstepped drill. This piece of material is joined tothe other piece and assembled with 30mm longself-tapping screws, which once driven into thematerial will provide a strong joint. No pilot holeis required, but wood glue should be used toprovide a strong long lasting joint. The screwremoves the need for clamping and thecomponent can be handled whilst the glue isdrying.

It is ideally suited for use with 19mm (3/4") thickmaterial because the distance from the base ofthe jig to the drill guide, combined with the angleof the screws, causes the screw to exit the19mm material at its centre.

An accessory stepped drill bit with collar isavailable with a 1/4" hex quick-change fitting,which allows faster tool change(Ref. PH/DRILL/95Q)

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ASSEMBLY & ADJUSTMENT

Setting Up The Jig

The Pocket Hole Jig can be used both fixed to abench or portably depending on the application.The most common position is screwed to abench and with the material clamped into the jig.

In the fixed bench position it is advisable tosecure material the same thickness as the jig,either side of the jig body. This makes it easierto slide large components into the jig and alsoprevents it tipping.

The built-in push-pull clamp arrangement allowsboth hands to be free for drilling in bothapplications.

For use portably, the jig can be clamped to theactual component. This is necessary for large orheavy components.

2

21 1

3

3

Always remove plug from power

source before making any

adjustments.

Setting the Push-Pull Clamp

To bore the pocket holes you will need to set theclamp position to ensure it holds the materialsecurely. The Pocket Hole Jig has two positionsfor fitting the clamp. The first position (A) allowsmaterial thickness of 16mm to 18mm to beclamped. The second position (B) allowsmaterial from 18mm to 38mm thick to beclamped.

■ Using the 3mm hex key loosen the fourmachine screws and remove them.

■ Move clamp back one set of holes andreplace screws and tighten securely.

■ Loosen the locking nut (1) on the clamp padstud (2) using a 12mm A/F spanner.

■ Screw clamp pad in and out to find the correctsetting. The correct setting is achieved whenthe clamp handle snaps closed when usingtwo fingers of pressure.

■ When set tighten clamp locking nut (1).

If the component moves when drilling the pocketapply more pressure with the clamp by screwingout the pad further.

A B A B

BA B A

(2) (1)

Setting Pocket Hole Centres

The pocket hole jig has variable distance drillguides to allow material of minimum width of38mm (1-1/2”) to be joined.

■ The adjustable guides canbe locked at variouspositions allowing holecentres of 29mm (1-1/8") to63mm (2-1/2") per set up.

■ Once the hole positionshave been decided, boththe drill guide columns canbe set equally using thescale and locked in positionusing the 4mm A/F hexkey.

29mm - 63mm

1 1 32 23

= =

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PH/JIG

Before using the pocket hole jig for

the first time, it is recommended that

a number of trial cuts are made in

waste timber as this will allow the

drill to bed into the drill guide bushes

in the columns. During the bedding in

process there will be evidence of

some metal swarf.

✗

A

B

15mm15mm

10mm

30mm

30mm

20mm

Setting the Drill Bit Depth

The depth collar on the drill is used to control thedepth of the pocket, which also sets the length ofthe screw that protrudes through and into thejoining piece.

■ To set the depth collar on the stepped drill,firstly remove the component from the jig,loosen the collar grub screw using the 2.5mmA/F hex key and place onto the shank of thedrill about 50mm down.

■ Lightly tighten the grub screw to lock thecollar onto the drill.

■ Put the stepped drill with collar fitted into thebushed hole in the column, until the collartouches the top of the bush.

■ Gently loosen the grub screw on the collarand adjust the depth of the drill so that theend of the drill tip is about 3mm above the jigbase (a packing piece or coin can be used).

■ Tighten the grub screw securely. The collar isnow set for 30mm long screws, which givesapproximately half of the screw into eachworkpiece.

■ Check collar position is correct beforebeginning to drill.

By adjusting the collar back or forward will give adeeper or shallower pocket. If the depth collarposition is set too deep the screw may protrude

3mm

through the face of the jointing piece. If tooshallow the screw may not enter into the jointsufficiently.When working with thin material (16mm) andmitres, the counter-bored hole will need to beshallower than standard. Shallower counter-bored holes will result in the head of the screwbeing closer to or even above the surface, this isacceptable in certain applications where thehead of the screw is invisible from view.

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Material Thickness

The jig can be used on material from 16mm to38mm thick. If the material is thinner thanoptimum 19mm thickness the screw will not exitin the centre and likewise if thicker material isused. Even though the screw does not exit inthe centre a tight joint will be still be created. Asthe material gets thicker however it may beadvisable to put pocket holes on multiple sidesof the component.

OPERATION Pocket Hole Spacing

When boring framing material, two pocket holesshould be used to keep the timber from twisting.When working with long pieces of timber tocreate a board (jointing edge to edge) to make atable top for example, single pockets can bedrilled at between 150mm to 200mm centres.

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Use a high drilling speed to increase

drill life (2000rpm or higher).

Keep the drill bit sharp.

Make sure drill bit is held in chuck

securely. If the drill spins loose in the

chuck the shock can break the drill

bit tip.

Place the drill bit into the top section

of the drill guide hole before spinning.

Do not place the drill tip against the

component until the drill is at full

speed. Do not push hard on the drill

until the drill pilot tip of the drill bit is

fully into the work piece and the

counterbore section is actually

cutting.

Drilling the Pocket Holes

Boring the counter-bored hole involves drillingwith a stepped drill into one of the joint pieces.

■ Fit the material to be pocket hole drilled intothe jig and clamp tightly.

■ Fit the drill bit with depth collar already setinto the chuck of the drill used.

■ Place drill bit into top section of the bush holein drill guide. Do not place the drill tip againstthe component.

■ Switch on drill at full speed (clockwisedirection) and drill into the component untilthe collar touches the bush. Gently pullingdrill in and out whilst drilling will allow woodchips to clear more easily.

■ Once depth is reached switch drill off andwithdraw drill bit from drill guide.

■ Repeat for other pocket hole and then removecomponent.

■ Repeat operation for the remaining pieces.

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Assembling the Joint

Self-tapping pocket hole screws do not need tohave pilot holes drilled, even in hardwoods.Other types of screws can work in the jig but theself-tapping screws reduce splitting in the timberand are hardened to reduce breakage.Whenever possible use glue on the joint unlessit is necessary to disassemble the joint.

To aid assembly on corner joints, it is advisableto use a high batten, clamped to the bench. Thecomponents can be pushed against it to keepthe two parts flush to each other, whilst screwingthem together.

When assembling edge to edge joints it isadvisable to use the face clamp to keep bothparts flush. The face clamp can be adjusted tosuit material thickness by adjusting the lockingnut on the handle of the face clamp. The largerpad on the face should be on the face side ofthe material.

The screw should be driven into the componentusing a torque control screwdriving drill. Thetorque control allows control of the tightness ofthe screws into the wood and minimise thepossibility of stripping the screw. The longersquare drive screwdriver bit is used for mostpocket hole screw driving applications. Theshorter bit allows for use in tight spaces. Thescrewdriver bits have 1/4" quick change shanksand can be used directly into a drill chuck ormore conveniently into a Snappy quick changedrill chuck Ref. SNAP/QC.

If a torque control screwdriver is not availablestart to screw with a conventional drill and thenfinish off by hand using a square drive handscrewdriver or the Snappy Handriver Ref.SNAP/HAND/1.

If access to the screws are tight the screwdriverbits can be fitted into a 1/4" socket fitted to aratchet or use a flexible shaft screwdriver.

Bench

Batten Component

Component

Square Drive Bit

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PH/JIG

APPLICATIONS

Frame Corner Joints – faster and stronger thandowel and biscuits. Self clamping whilst glue isdrying.

Mitred Frame Corner Joints – for narrowframes a single pocket hole is necessary. Cutthe mitre and rout any rebates before boring thepocket holes. For material less than 50mm wideit may be necessary to tilt the pocket hole pieceso that the hole is not perpendicular to themitred edge.

Square Corner Joints – faster and strongerthan dowel and biscuits. Self clamping whilstglue is drying.

T- Joints – faster and stronger than dowel andbiscuits. Self clamping whilst glue is drying.

When changing material or joint

application, test the depth of the drill

and collar before drilling into the

workpiece. Test drill in waste

pieces of the same thickness. Then

drill a screw into the pocket joint only

and lay it against the jointing piece to

see if screw depth is correct.

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Angled Joints – eliminates difficult clamping up.The joint is created not by cutting each mitre tohalf the angle but by cutting angle on onejointing piece and drilling pocket holes into thesquare piece. The method results in the mitrededge having an overhang, which will need to beremoved by plane or sander.

Curved Joints – this uses the same techniqueas the angled joint, but the angles will beshallower (5° to 15°). The overhang will need tobe removed as previous.

Mitred Corner Joints – joining two pieces with45° mitres with the pocket jig is not advisable,however a 90° change of direction can becreated by using a bevel-jointing piece. The jointcomprises of a 90° infill piece with 45° mitres onboth sides.

Plinths – faster and stronger than dowel andbiscuits.

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Edge to Edge Joints – allows narrow strips tobe jointed to create wider boards such as a tabletop.

Post and Rail Joints – pocket holes allowstrong table and chair joints. For fitting tabletops to rails, the rails will need to be pocket holedrilled. To allow for the movement of the timberas it expands and contracts the hole must beslightly over size. This is achieved by lifting therail about 3mm off the base of the jig. Thisshould allow the pilot tip of the drill to breakthrough the end of the timber, giving the screwspace for some movement. Alternatively movethe rail sideways slightly to drill another pockethole (interlocking) allowing a slot for the screw.

Edging of countertops or shelving – quick andeasy way to join edging onto plywood, MDF orParticle board shelves.

Jig making – very useful for jig making andtemporary assembly operations. Ideal forrouting jigs.

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PH/JIG

Framed Panel (Cabinet) Joints – pocket holescan be used for almost all framed cabinetcarcass construction.

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ACCESSORIES

Self Tapping Screws Square drive

No.7x30mm.Pack 500Ref. PH/7X30/500

Quick Release Shank Drill Bit

Ref. PH/DRILL/95Q

Pocket Hole Plug Cutter

MAINTENANCE

The accessory has been designed to operateover a long period of time with minimum ofmaintenance. Continual satisfactory operationdepends upon proper tool care and regularcleaning.

Cleaning

■ Keep the threads and clamp mechanism clearof sawdust and resin build-up.

■ Regularly clean with a soft cloth.

Lubrication

■ Periodically lubricate the holes in the guidecolumns with PTFE dry lubricant egRef. TRENDICOTE™.

Drill Bit Care

■ Ensure the drill bit is sharp.

■ Check tightness of depth collar set screw.

ENVIRONMENTAL PROTECTION

Recycle raw materials instead of disposingas waste.

Packaging should be sorted for environmental-friendly recycling.

The product and its accessories at the end of itslife should be sorted for environmental-friendlyrecycling.

GUARANTEE

All Trend products are guaranteed against anydefects in either workmanship or material,except products that have been damaged due toimproper user or maintenance.

A tool steel pellet cutter that isused in a pillar drill to allowplugs to be made to cover thepocket hole.

Allows plugs up to 52mm longto be created in end grain.Ref. PH/PC/95

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PH/JIG - SPARE PARTS DIAGRAM v2.0 08/2003

PH/JIG

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PH/JIG

Fault Cause Remedy

■ Clamp will not lock in Clamp pad not set to correct Adjust clamp pad length by holding position. position. rotating pad, until clamp handle

snaps closed when using two fingers of pressure.

■ Drill guide columns move Fixing screw not tight. Tighten fixing screw with hex when drilling. key.

■ Screw protrudes through Depth collar set to high causing Adjust height of collar on drill bit. face of mating piece. drill bit to drill too deep.

■ Workpieces will not pull Occurs on very hard woods, Clamp material more tightlytogether tightly when when threads of self tapping or adjust collar so drill pointbeing assembled. screw are holding on both nearly breaks through first

pieces of material and pushing piece of material.them apart.

■ Workpieces do not sit Screws tend to follow grain of the Clamp more securely to flush or move when being wood. prevent material movementassembled. when assembling. Use face

clamp for edge to edge joints.

TROUBLE SHOOTING

PH/JIG - SPARE PARTS LIST v2.0 8/2003

No. Qty. Desc. Ref.1 1 Jig Body WP-PHJ/012 2 Guide Column with Solid Bush WP-PHJ/023 1 Guide Column Rod WP-PHJ/034 1 Guide Column Nut WP-PHJ/045 1 Machine Screw Dome M6 x 12mm Socket WP-SCW/726 1 Push-pull Clamp Complete WP-PHJ/067 1 Push-pull Clamp Adjustable Pad & Stud Assembly WP-PHJ/078 4 Machine Screw Dome M5 x 10mm Socket WP-SCW/719 1 Stepped Drill 9.5mm (3/8”) Diameter x 150mm

Long HSS PH/DRILL/9510 1 Depth Collar for Stepped Drill PH/COLL/9511 1 Snappy Square Drive Screwdriver Bit No. 2 x

75mm long SNAP/SQ/2A12 1 Snappy Square Drive Screwdriver Bit No. 2 x

150mm long SNAP/SQ/2B13 1 Screw Pocket Hole Self Tapping Dome No. 7 x

30mm Square Pack of 500 PH/7X30/50014 1 Hex Key 2.5mm A/F WP-AP/2515 1 Hex Key 3mm A/F WP-AP/0316 1 Hex Key 4mm A/F WP-AP/0417 1 Face Clamp 152mm Long x 42mm Throat x

42mm Opening PH/CLAMP/F618 3 Bench Fixing Screws Csk No. 8 x 25mm Pozi WP-SCW/10019 1 Manual MANU/PH

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© Copyright Trend 2005. 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

Trend Machinery & Cutting Tools Ltd.Odhams Trading Estate St Albans RoadWatford WD24 7TR EnglandEnquiries: __________________0800 487363Technical Support:____0044 (0) 1923 224681Fax: ________________0044 (0) 1923 236879Email: ______________enquiry@trendm.co.ukWeb:____________www.trendmachinery.co.ukRECYCLABLE

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