Plunge Router for use with Leigh D4 jig
grindstone | Posted in Power Tools and Machinery on
I’m shopping for a new router to use with a Leigh D4 jig. Any recommendations regarding fixed vs. plunge? I have a PC fixed based but would like to add a plunge rounter for other use as well. Any preferred brands?
Replies
I've got a Dewalt 621 that I use with mine. I like it, its easy to adjust, and my wife bought it for me. If I bought another one though, just for the D4, I'd get a fixed base. Less mass to manhandle. I've always thought the Bosch looks like a good machine. I try to avoid routers as much as possible though, so someone else might have a better opinion.
As a matter of fact, I just bought a Dewalt 621 today to use on my new Leigh FMT ( how's that for a double gloat ). When I'm using the D4 I prefer my PC690. I also have the mortice template for the D4 and was using my PC7529 with it. While I like it to use freehand, I found it top heavy on the jigs. I've found the DW621 much more suitable for use on the FMT and on the D4 with the mortice template. But I still prefer the fixed base PC690 on the D4 for cutting dovetails.
Brent
There's always the possibility, however slight, that the inadvertent release of a plunge mechanism could chew the heck out of a dovetail jig; sounds like another reason to advocate a fixed-base router for use with a dovetail jig.
-Jazzdogg-
"Don't ask yourself what the world needs. Ask yourself what makes you come alive, and go do that, because what the world needs is people who have come alive." Gil Bailie
Edited 9/3/2005 11:09 pm ET by jazzdogg
There are precautions (always) with any router. Notwithstanding, the cutter in a 621 (surrounded x collar) cannot rise up and kill the templet. Kill the collar yes, but not the templet. No doubt, if the router is picked up, you can spoil anything from protoplasm to templet.
There are (fewer each year) plungers with up-stops (PC 7539, DW 625 e.g.). If the up-stop is set to zero and the motor locked, then the motor can neither go up or down; it's stuck in place.
Dovetail cutters, however, do spontaneously change depth! With dovetail cutters there is a vector (a force with a downward direction) that is constantly pulling the cutter from the collet. Use less than the customary 15 inch-pounds of collet tightening torque and you might lose depth (actually cut more material) while routing. If the cutter has ever slipped in the collet (before) expect it to change depth. A burr on the shank or a snookered collet will let a cutter slip.
Dovetailing is the meanest router chore there is. Cutters are skinny, cutting depths excessive; expect adversity!
Routers
Well said, Pat. As expected, a cogent, well-reasoned explanation based on extraordinary experience and insight.
Thanks!-Jazzdogg-
"Don't ask yourself what the world needs. Ask yourself what makes you come alive, and go do that, because what the world needs is people who have come alive." Gil Bailie
PC690 or newer versions works well. Do not use a plunge router -- only fixed base. See post above about messing up dovetail bit or fingers on D4.
I'd avoid the plunge base on the PC 890 series. Not just for this purpose, but for this one especially.
I bought the PC 895 plunge/fixed-base combo a while back, and it leaves alot to be desired. As others have reported, the router in the plunge base tends to "wiggle": if you push down on the right handle, the bit will swing side to side, On anything as precision as a D4, that's asking for trouble. It is very tricky to try to control the router by holding on to the rigt handle, but to not ruin the piece by putting any downward wieght on it.
The fixed-base is pretty sloppy, too. I bought the PC 895 on the track record of the 690 series, but PC has screwed up on this one.
I have two Ryobi 500 series plunge routers that I've used with my Leigh for almost 20 years. Only once in that time did the locking mechanism "slip" (meaning I didn't wank it down well enough) and chewed up the work and finger.
More frequently the problem has been the bit not being held by the collet. It sucks to finsh routing a series of tails, and then see how each one is about 1/16" depper than the last one! Again, it was due to me not tightening the bit enough. Now I always check collet and plunge lock twice before starting.
Of course, using plunge routers means I don't have to buy yet another router for non-Leigh work.
Hi, I have the D-4 and the FMT jig, I bought a PC 690 cobo pack and now have a decicated base for both units. I also have a second 690. works great with everything
I use my festool 1010 with the Leigh. I like the light weight and the ergonomics. You don't need a lot of router to drive those 1/4 inch or 8 MM cutters. The Festool is a plunge router, but I've not had any problem with inadvertent "plunges".
Regards - Seth
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