Mid-Sized Plunge Routers

This month I'd like to discuss mid sized plunge routers, those falling in the 2 1/4 horsepower and under category. 

We will start with the Porter Cable Model 693. It is a 1 1/2 hp, 10 amp motor that features 23,000 rpms. It has a plunging depth of 2 1/2" and weighs 11 1/2 pounds. It will accept all router bits, as it comes standard with both 1/4" and 1/2" collets. It also features a depth rod and 6 position step turret for easy depth adjustment setup. As with all Porter Cable routers, this is a wonderfully built machine. The best feature is that the motor is removable, and can be used with Porter Cable's "D" handle base or their fixed base for hand routing applications. This makes it one of the most versatile routers on the market. If you are planning to mount this router under a table, I would suggest the addition of a fine tune height adjustment knob. Without this accessory, adjustments tend to be difficult.

I will break up the discussion into two different categories: straight plunge routers, and combo kits that include both fixed and plunge bases with one motor. Let's start with straight plunge routers. These routers look like something out of Star Wars, however they are actually state of the art machines. 

Before we go on to the DeWalt model, let's take a moment and discuss variable speed in a router. Is it necessary, and if so, for what purpose? The answer really depends on your use. Most hand routing applications really can be accomplished without variable speed. Where it becomes imperative is when you are running larger router bits such as raised panel bits, or stile and rail cutters. Basic rule of thumb is that the larger the bit, the slower you should be running it. When the router is mounted under a table, you are usually more apt to tackle the larger projects that you might avoid if using the router by hand. With that in mind, my advice is even if you don't see a real need for it today, it might be necessary in the future. Also, if you are in the beginning stages of woodworking, running the router slower is a good idea, so all in all, variable speed is something I would recommend.

Now let's move on to the DeWalt DW621. This router is 2 hp, 9.7 amp and is also variable speed between 8,000 and 24,000 rpms. It includes both 1/4" and 1/2" collets, a micro fine depth adjustment knob, and uses the same type of template guide system as Porter Cable models. The plunge locking mechanism is built into one the side knobs which you turn to lock and release. This make the plunge mechanism the easiest and most efficient of them all. This router also features a built in dust extraction port. The dust is sucked through a clear plastic insert on the base of the router, and travels through a large hollow post surrounding one of the plunge posts. The debris then exits the unit through a plastic "L" shaped port at the top of the post, and to your shop vac. One wrench is all that is needed to change your bits on this unit.

Next in line is the Porter Cable Model 7529. It has a 12 amp, 2 hp motor, with variable speed of 10,000 to 23,00 rpm's. It comes standard with both collets, microfine depth adjustment knob and a spindle locking mechanism.

All three of these tools are of incredible quality and it is hard to recommend one over the other. The bottom line here is you would be making a smart purchase with any of these models.

It's time to shift our focus to the combo kits. These kits are very popular due to their versatility. What you get is a motor with both a fixed base and a plunge base, 1/4" & 1/2" collets, all packaged in one convenient carrying case. One of the bases is used for hand routing, while the other can be permanently mounted under a table for table routing applications. The motor is easily removed from one base and place into the other so that you are not paying for two separate motors. There are presently models available by many manufacturers including Bosch, DeWalt, Porter Cable and Makita. Most offer the same features and benefits, with the biggest difference being the horsepower rating. As stated with the other plunge router category we discussed earlier, I suggest at least 2 hp with variable speed. Based upon this, as well as feedback from customers, my recommendation here is either the Bosch 1617EVSPK or the DeWalt DW618PK, with both the Porter Cable and Makita getting honorable mention.

If you have any questions about routers, or any other tool, feel free to e-mail me and I'll be glad to assist.

Speak to you again next month!

Comments, questions and/or ideas for future articles are also appreciated.

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Read previous months' tips:
Cabinet Tablesaws
Slide Compound Miter Saws
Mid-Sized Plunge Routers
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Detail Sanders
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Hammer Drills