Routers, what I use and why

[formariz 11,865]

 

The question about opinions regarding routers in another post prompted me to write this one, since not only I have used them extensively in my career but I have many times been asked why I own so many and why my choices.  

  In my line of work aside from drills they were  the most used power tool. From laminate trimming , rabbeting, molding, chamfering , lock mortising, etc, etc, they are indispensable for their speed ,versatility and general utility. They were used daily many times entire consecutive days on end. Because of such an extensive usage it became evident what models and types were not only the most reliable but also comfortable and above all safe since i did things with them that most people never have the need  for. They were even used to undercut doors ,thing most unheard or snubbed on by some , but when you are dealing with a $10,000.00 custom made door with exotic veneers , a circular saw is the last thing you want to put on it for reasons that can be explained. Wearing them out, damage from dropping, and the fact that many times several individuals would use them and not be so kind to them were all also facts in deciding what was best.  As far as price it quickly became evident as it always is that one gets what one pays for, so it was the least important factor since money saved on a tool is many times money lost on a job due to break down or difficulty in use or and setup. 

  

 The ones I own now are vintage since they have proved themselves just in the fact that they are still here and as good as the day they were bought so there is no need to buy a new one with the latest frills which many times amount to nothing. I have used them and quite honestly with one or two exceptions I am not impressed. There seems to be a necessity to reinvent the wheel or dazzle with features that quite honestly may be impressive looking at , reading about but when it comes down to actual real use mean nothing. Almost like a Wheelhorse compared to new big box store models. 
 

  

  The important things to me in a router are the following in the order they are stated. 

 

1- Safety. Where is switch located and how fast can one get to it? Do I need to take my hand off handles to shut it off or start it? Does switch location change with adjustments?

 

2- Comfort.  How comfortable is unit to use? Is it well balanced? Is it top heavy? Does it vibrate excessively? Can it be used comfortably for an entire day? 

 

3- Adjustability. Do they hold hour after hour of usage. Can adjustments be locked in by hand alone ? Can it be adjusted safely while running without taking one’s hands entirety off handles? If so are adjustments smooth and predictable or are they jerky or stiff?

 

4-  Durability. How well built is it?  How durable is base? Will an occasional drop be catastrophic to the base and therefore to routers accuracy? Are adjustments precariously exposed prone to damage?

 

5- Flexibility and accessories.  How available are accessories such as special guides, template guides, collets, etc.  Are they proprietary or universal? Do most molding bits fit in base or base needs to be modified? 

 

I own quite a few routers since they are dedicated to specific functions or cutters, but will list only a few since they are always Makitas, Dewalts ,Porter Cable or Rockwells. I will stick to full size routers and not trimmers I’ll start with  my favorite ones and their qualities. Plunge routers are my favorites. They are the most versatile and if a good one the most accurate.

 

 Makita 3612 BR. Japan made.In use since 1986

This router embodies everything I have mentioned above. Perfectly placed and oriented handles and everything in reach of right hand.

 

 Switch conveniently and safely located next to your index finger. Can be switched on and off without removing hand from handle. 

 

lock also conveniently located

 

again adjustable while holding handle. Adjustments are easy and smooth. More so while router is running.

 

Preset depth stops also able to be operated without releasing handle

 

 Router is perfectly balanced regardless of adjustment. Handles are placed at router’s center of gravity making for steady totally controlled use. 

 Large guide with micro adjustments , sturdy well placed posts.

 

 Just about any cutter fits through base

 

 Unique template guide system easy to install and remove which will stay securely attached unlike most others perfectly concentric with base and shaft.

 

 Lockable shaft and high quality wrench

 

2-1/4” plunge capable as per manafacturer

 

plunge capability actually able to be stretched safely to 2-7/8” allowing longest available cutters to be used 

 

 Base is perfectly concentric to cutter  which is not so with many. Newer models also have a flat spot to be used with a guide. Phenolic bottom perfectly aligned with base. 

 

 Makita 3612 BR  also made in Japan in use since 1992

 This router has always been adapted to my router table. It is absolutely incredible the hard use that this machine has had. It is always used with large cutter’s sometimes entire days on end .  Same bearings and brushes . A testament to its quality. 
 

 

 Besides removing handles i adapted a height adjustment from an older model to make it convenient under table. It is easily adjustable just with finger tips as shown.

  Type of cutters this router has lived with all of its life.


 

 

 US made Dewalt type 1 of this model.Had it probably 25 years. Good solid reliable fixed base router. Sturdy construction and comfortable. A little top heavy but better than most of this type. Another favorite 

 

 Good adjustment system keeps motor in same orientation and keeps switch in same place next to right hand.precise adjustments which stay put.

 

 

 Bottom of bases on this type of router are terrible. Cutter hole always too small and phenolic base rarely concentric to cast case and therefore cutter. Clear plexiglass bases remedy that and allow greater visibility.

 I have several separate bases for these models dedicated with different template guides

 

 Dewalts and Porte Cable use a standard template guide. Great availability and size choice but problematic due to low quality bases which are also inconsistent in thickness. They are difficult to install or remove quickly sometimes requiring using channel lock and getting loose while usage from vibration. Holes for them in bases are also always oversized allowing guide to favor one side or other reducing accuracy important such as when routing inlays .

 

  Bases on these routers are notoriously fragile as evidenced in the router cemetery here.

 The good is the different size availability 

 

 Old Rockwell also probably over 30 years here. A work horse dedicated to precise edge trimming or cleaning of MDF or composite materials using it with a dedicated fence. Well built but not a good design which I will get into on next one. The best thing about it is the handle providing great control specially how it is used. I made rectangular base for stability and accuracy to be used with dedicated fence. 

 

 

 

 

  Last but important for all the bad things present still today in many. Old Porter Cable probably here for 20plus years. Good motor but very bad design.

 

 Extremely top heavy. Very hard to control and use. if used with intended fence ,posts are too close together making fence unstable and flexible. Fence posts are also too thin for routers weight. Plastic top unforgiving to the slightest drop. 

 

 Motor twists on base to adjust height. Typical of this brand . Effect is that places switch always either on wrong side or away from right hand. Not an easy router to control with one hand. Same feature makes adjustment erratic and unable to achieve any type of precision. Rotating motor also creates more lack of precision in base already not concentric with cutter. Totally unpredictable. Not good for precision work.

 

Tightening system although rugged looking does not lock or hold well needing a tool so one is sure that  motor will not come loose. Never use a router of this design in overhead operation . Outright dangerous.

Edited February 17 by formariz

[JimSraj 346]

I also have a small collection of routers that I’ve accumulated over the years. The first one that I bought, back in the mid 80’s, is a Milwaukee 5680 fixed base. It is still with me and working as it has for all these years.  Never had to do anything to it other than new brushes about 10 years ago. It’s been upside down in a table for a number of years now. Also have an older Bosch fixed base, I think it’s a 1604, that I bought at a garage sale for a few $$. I don’t care for the on off switch being located on the top where it’s near impossible to reach with hands on the handles but it is a very strong router. Problem with it now, is that the mechanism to tighten the base is a proprietary wing nut that squeezes the base metal against the body of the router. One of the wings broke off and the part that houses it on the base cracked as well. I’ve got a big hose clamp on it that works but it’s very awkward to use. I’m told that the Porter Cable 690 base fits and works well but haven’t been able to find one nor can I find the Bosch base that goes with the 1604.  Another newer Bosch 1617, with both fixed and plunge bases, as well as a big Porter Cable 7538 and a Milwaukee 5625 round out the 2 handed routers in my shop. Several smaller laminate trimmer types for lighter duty.