Plunge Router

[Michael Moscicki]

I've got 2 fixed based routers which are worthless and am in need of a handheld plunge router. I'm looking at the used market as I can get them 50-60% off versus buying new.

I'm really interested in the Porter Cable 7539 3 1/4 HP plunge router. It's the old one that was still made with pride in the US, before they were sold to Black and Decker and moved to Mexico/China.

At 17.2 pounds is it too heavy for handheld work? Should I look for something lighter or is the weight a non issue? Any others to consider? Also what is the lifespan on a router, I mean how long should I expect it to run before it dies on me(I've heard people with PC routers that have used em for 25+ years, so the PC should be a safe bet)?

Side question:

Is "Woodworking for Dummies" a good beginner's book, or should I pick up a different book?

[Greg Peterson]

Michael - Dewalt and Bosch have their fans. The older P&C are good. As for a 17 pound router for plunge work, I can think of a lot of plunge work I would not want to try to manage that much machine. I guess it depends on what your plunging task is.

As for books, that again depends on what your immediate and mid range plans are in the craft. Boxes, cabinets, furniture....?

[Michael Mayo]

Look for a Bosch 1617 plunge router. I got a used 1617EVSPK which is a kit that comes with a plunge base and a fixed base. This router is awesome and i love the plunge base. It is very easy to maneuver when doing handheld routing and the weight is a none issue. That 17 lb. router isn't going to be fun to try and move around when doing handheld plunge work.

[Michael Moscicki]

Michael - Dewalt and Bosch have their fans. The older P&C are good. As for a 17 pound router for plunge work, I can think of a lot of plunge work I would not want to try to manage that much machine. I guess it depends on what your plunging task is.

As for books, that again depends on what your immediate and mid range plans are in the craft. Boxes, cabinets, furniture....?

For plunge work, I need to make some mortise joints on a radiator cover that I've been procrastinating on for the past month or two.

As for the book, the only serious woodworking tool I have is a scroll saw and I've got that pretty much down pat. Big tools are out of the question since I have no shop and won't well to I get a place of my own, but easy furniture that can be made with no more than a router for joinery, cheap ryobi table saw for cutting to size, hand plane to joint the end I just cut, and a palm sander well for sanding. So basically an introduction book to help me get started, cover all the important topics and of course to stop me from posting on the forums every time I have a question. ;)

[Victor Robinson]

Woodworking with the Router by Bill Hylton is one of the most valuable books in my WW library.

[Michael Moscicki]

Look for a Bosch 1617 plunge router. I got a used 1617EVSPK which is a kit that comes with a plunge base and a fixed base. This router is awesome and i love the plunge base. It is very easy to maneuver when doing handheld routing and the weight is a none issue. That 17 lb. router isn't going to be fun to try and move around when doing handheld plunge work.

18.2 pounds, makes the PC 1 pound lighter. It does have 1 less horsepower, not that 2 /14 is bad, so I'll take another look at the bay(my craigslist is useless when it comes to routers at this time).

Using the weight specifications from Amazon, so it might include the box and all accessories.

[Michael Moscicki]

Easier question.

What's the max weight I should be considering for a handheld plunge router? I won't be making 1,736 box joints any time soon, so I doubt tiring my hands will be much of an issue. ;)

[Jerome Hanby]

Woodworking with the Router by Bill Hylton is one of the most valuable books in my WW library.

Mine too. His Router Magic is a good candidate for keeping it company...

[Jerry Thompson]

17.2 lbs., sounds more like a hand held shaper!:)

[Kent A Bathurst]

I'm far from being a router wizard, but my three PC690's, and 3 bases, do everything I've ever needed. A big honkin' 75xx seems way over the top for anything I could remotely imagine doing with a plunge base.

On if my 690's is about 12 years old, one about 6, one about 2 - it is the only one that is the newer 1.75 VS. I'm glad I have the VS, because sometimes I have to use big dia bits, and I need to slow the speed down. Other than that, the non-VS do great.

Those kits are frequently available used.

[Richard Wagner]

I have a Ryobi RE-600 that has never let me down. It has proven its worth to me. It, however, is heavy; weighing in at 13.6lbs. It is variable speed from 10,000 to 22,000 rpm.

[pat warner]

I was in on the R&D of that router; the prototype was 22 pounds.
There were a lot of compromises to turn that tool into a production router.
Will it last? For your work and utility? Forever.
Is it too heavy? Maybe. Appreciate that, for a single job, the coefficient of friction is more important. That is, will it slide well on your work?
If your work is such that you have to reload the work and get the router off the work time & time again, then it may be too heavy, lest you're a weight lifter.
Power? Probably the toughest big router extant. Tho the Bosch 1619 is a near equal.

[Bruce Page]

I have a PC7539 set up as a high speed spindle in my milling machine and a PC7518 in my table. I wouldn’t want to use either one in hand held mode for very long. The PC690 is my go-to for hand held routing.

[Richard Shaefer]

Don't discount the Dewalt DW621. I firly set this router as the best thing going this side of a Festool. I rather have a fully dedicated plunger any day of the week over one of those mix-n-match base kits, but that's a personal preference.

[Mac McQuinn]

I have a complete P/C 690 set up from about 12 years ago, U.S. made. D-Handle 691 with steel Carrying case + the P/C Plunge attachment. I really like the D-Handle for stability and the plunge attachment is a one bolt affair. Solid well made tool. I believe the HP is 1.5 or 1.75 although can't imagine needing any more power + it's light enough to handle easily. I'll be posting these for sale in the classifieds in near future if you're interested.
Mac

[Brian Tymchak]

I've had a Makita 1101 (2 1/4 hp) for 10? years and it has done all the hand routing tasks I've asked of it very nicely. I bought the kit with the plunge base and it works very well too. I plunge cut 3/4" wide x 3" deep mortises in Ash with it when I built my workbench. I don't know the weight of it but it is much less than the PC 7518 (3 1/4 hp) I put in my router table. I would recommend a mid-range hp router kit (with soft start) for hand work and maybe a trim router (Bosch Colt VS was my choice) for small detail work.

[Michael Mayo]

18.2 pounds, makes the PC 1 pound lighter. It does have 1 less horsepower, not that 2 /14 is bad, so I'll take another look at the bay(my craigslist is useless when it comes to routers at this time).

Using the weight specifications from Amazon, so it might include the box and all accessories.

The Bosch site says 19.5 lbs. but that has to be for the complete kit with both bases and accessories. I will weigh my Bosch with the plunge base on it and let you know what it weighs as now you have me curious.

[Michael Mayo]

Don't discount the Dewalt DW621. I firly set this router as the best thing going this side of a Festool. I rather have a fully dedicated plunger any day of the week over one of those mix-n-match base kits, but that's a personal preference.

I have the Bosch 1617 EVSPK kit and I honestly couldn't tell you great this kit is. The fixed base works great in my quickly thrown together router table wing on the TS and the plunge base is awesome. Very accurate controls and setup and very easy to use.

[John Coloccia]

I have the Bosch with the plunge base. I just weighed it. It's about 10.5lbs.

[Jerome Hanby]

I think that's just about impossible to answer definitively. It all depends on the user. I think a heaver router is more stable, but if it's too heavy for you to wield easily, then it doesn't matter how stable it is. I think you have to pick one like you'd pick out a ball at the bowling alley. Try a bunch until you find the heaviest one that still feels good in your hand and you can still swing.


Easier question.

What's the max weight I should be considering for a handheld plunge router? I won't be making 1,736 box joints any time soon, so I doubt tiring my hands will be much of an issue. ;)

[Rick Fisher]

I have the PC 7518 In a table.. Its likely not quite as heavy but its still a beast.. I don't prefer it free hand.. its way too heavy.. My favorite router is my 1400 Watt Festool which I believe weighs 10-1/2 lbs.. Its about the perfect weight.. At 1400 watts.. its about 12 amps. I have never found it short of power. Truly impressive.. Right now I am cutting large and deep mortises with a 1/2 Spiral bit.. Power is not a concern..

I would suggest any 2-1/4 hp router would be as powerful as my Festool.. Its more than powerful enough for freehand work.

The only fella's I know who use the Big PC Plunge Routers are Curved Staircase guys..

[scott spencer]

I've been really pleased with the plunge on the Milwaukee 5615/5616. Very smooth, very well made, accepts standard bushings, and the motor on my 5615 says Made in the USA. I also like the BodyGrip feature on the fixed base.

[michael veach]

I have used PC690s for years. They are pretty bullet proof. I had a plunge base for it but it wasn't comfortable to use. I recently purchased a Bosh 1617evspk. After using it to finish building my kitchen cabinets, I bought another one. As far as bushings. you can use the Bosh bushings, get an adapter, get the Bosch plate for PC type bushings or mount a PC plate to the Bosch without any modification.

[frank shic]

17.2 lbs., sounds more like a hand held shaper!:)

lol yup yup... those PC's are notoriously heavy!

[John Piwaron]

I'm extremely proud to say I own one of those bad boys. It's the Godzilla of routers. They will be prying it from my cold, dead, hands. It's going to be mine for the rest of my life.

If you can find one someone is foolishly willing to part with, buy it. It's worth it.

[Michael Moscicki]

I can buy the 690 with fixed base on the bay for $80(based on how a similar one sold) with shipping. Auction ends in a few hours. Then I would have to hunt down a plunge base.

Or

I can let it end, and try my luck at the 690 with fixed and plunge base which ends in 5 days. The last one spiraled out of my price range($150 with shipping).

But yea, dead set on a 690, even if the plunge action is a bit quirky. I'll post pics when one gets to my door, don't you worry.

[Michael Moscicki]

Is the variable speed a deal breaker or can I live with out it for just joinery, round overs and maybe the occasional sign/design. Don't plan on using any panel raising bits anytime soon.

[Homer Faucett]

While I don't spin 3" bits in my big brute plunge router, I do appreciate the ability to vary the speed. Anything other than straight bits and small roundover bits generally get dialed back a bit. It all just depends on your future plans for the router . . . but if you're already buying the big bruiser, you're going to have it a long time. I'd go for the variable speed (honestly, I haven't seen too many for sale around here without the vs).


Is the variable speed a deal breaker or can I live with out it for just joinery, round overs and maybe the occasional sign/design. Don't plan on using any panel raising bits anytime soon.