Recommendations on Medium Dedicated Plunge Router

[Thomas McCurnin]

My beloved Porter Cable 2 1/2 hp 7529 died. It was a popular design in the 80s similar to the famous Elu 3338 and was light weight yet with power and a 1/2” collet. I am looking to replace it.

I have a half dozen routers and this fills a particular niche for template routing of mortise and tenons with a shop made jig attached to my bench and it will be held up in the air at shoulder height, so weight is a factor and the smaller is better to a point. The dedicated plunge routers have better balance but I haven’t tried one of the new combo kits in DeWalt or PC model line (PC 893 or DeWalt 618 ). Nor have I tried any of the big boy plunges which are usually 11-12 lbs (DeWalt 625). My requirements are:

—2 hp or so
—1/2” Collet
—Dedicated Plunge (not a combo kit)
—Will not be anywhere near a router table
—Must work with Porter Cable guide bushings
—Should be light

I like the looks of Bosch 1617evs but will it work easily with my PC guide bushings?

I also like the DeWalt 621 at 9 lbs but don’t have a lot of information on it.

Porter Cable doesn’t seem to make a mid-sized dedicated plunge router anymore but I could missed it. Makita and Ryobi also abandoned that product line.

I could be convinced to go with a combo kit or one of the big boys if any of you have real world experience but would prefer a medium sized dedicated plunge.

Thanks in advance to all who respond.

[Stephen Rosenthal]

Thomas,

The Bosch 1617evs will accept PC guide bushings with the Bosch RA1129 adapter kit. Readily available from many sources for less than $10.

[Peter Kuhlman]

What you will miss after the 7529 is the awesome depth adjustment. Mine is the only router I have ever found that the micro adjust works with no need for depth stop screws. It is by far my favorite mid sized router and I have a pile of them. If 1/4” shanks will work for you I recommend the Festool OF1010 for it’s great balance and ease of use. In the 2hp range every router I found has serious compromises. i have a couple different Dewalts and the Festool 1400 and don’t like using any of them. I had the Dewalt 621 years ago and gave it to my son. It was a very nice router. The ones they sell now are made in Mexico last I knew and were not near as well made as the earlier version. If you can afford it move up to the Festool OF2200!

[David Stone (CT)]

I've had a DW 621 for probably fifteen years and it's just a really, really nice tool -- well designed, enough power for most things without being too big or heavy, simple, precise depth control and a very nice accessory fence. It also has integral dust collection, though I don't use that often. I think it's probably the closest thing on the market to your old PC.

I also have the DW 618 with both the fixed and plunge bases. It's very good, too, but, only having a 1/4 inch collet, it's a different animal -- a great complement to a 2 HP router, and better within its rightful domain, but not a substitute.

Years and years ago, I had a Ryobi 3 HP plunge router. It was overkill, and clumsy, for most things I'd use a plunge router for and I've never felt the need to replace it. (A 3 HP fixed base router, by contrast, is useful and great in the router table).

[Jim Becker]

David, the Dewalt DW618 handles .25", .5" and 8mm collets with no issues. I have all three for my DW618 kit. Perhaps you mean a different Dewalt model.

OP, the Dewalt DW621 is a well spoken of dedicated plunge router and has very good dust collection compared to most routers.

[Edwin Santos]

Hi,
I vote for the Dewalt 621. It is essentially a re-branded Elu router and though it has been out for a long time, the design was ahead of it's time.

[David Stone (CT)]

Oops, you're right: I was referring to the little guy, which I wrongly recalled as the DW 613 when it's actually the DW 611.

[Tom Bain]

The DW621 gets my vote. Just have to get used to the somewhat finicky “double trigger” switch.

[Earl McLain]

As noted, the Bosch 1617 can accept PC bushings with the Bosch adapter...or...if you remove the sub-base plate from the 1617's fixed base you'll also find the PC 690 hole pattern tapped. If you have base plates with the the 690 triangle mounting holes, they are plug-n-play.
earl

[Dave Sabo]

Thomas , have you considered looking for another PC 7529 or 8529 on eBay or Craigslist ? I see them from time to time , often less than $100.

Bosch made a similar router labeled B1450 and 1613. They have the same depth adjustment knob as the subject router. I'm not positive but the 1613 may have been discontinued too. All take the PC bushings with the adapter ring. I have both routers with both guide bush setups and the PC is just a much smoother and refined tool. However , the Bosch is much tougher and the bayonet bushing system is easier, faster and better for changing them out.

[Carl Crout]

Thomas,

The Bosch 1617evs will accept PC guide bushings with the Bosch RA1129 adapter kit. Readily available from many sources for less than $10.

I don't care for Bosch' system at all. Even with the adapter mentioned above there is still slop in it. I have two Bosch 1617 and I put new base plates on both that have the hole for PC guide bushings. You can get a blank plate at Eagle America

[Derek Cohen]

Hi,
I vote for the Dewalt 621. It is essentially a re-branded Elu router and though it has been out for a long time, the design was ahead of it's time.

If I was purchasing a new mid-size router, it would be a toss up between the Festool OF1400EQ and the DeWalt 621. I have the Elu predecesor version of the DeWalt, the Elu MOF97. It is a fantastic router - excellent fine adjustment and the best dust control I have experienced in a router. The Festool also has great dust control, and this is a big factor for me as the router is one for using hand held.

Regards from Munich

Derek

[Alan Schwabacher]

I don't care for Bosch' system at all. Even with the adapter mentioned above there is still slop in it. I have two Bosch 1617 and I put new base plates on both that have the hole for PC guide bushings. You can get a blank plate at Eagle America

A new base plate is a good solution. What I noticed about the Bosch is that if I let the spring alone lock in the adapter for PC bushings, some slop remained. If I also pushed in the direction the spring pulls to tighten it a bit extra, the slop went away.

[Myles Moran]

Yea, I have the 1617evs and if it's tightened I have no slop. I like it because I can get my fat fingers in more easily with that system to position the bit and tighten the collet and such. Less working in a tight spot.

[Thomas McCurnin]

My power tool store guy (yes I still shop at a brick and mortar store) recommends the Porter Cable 890 over any 1/2” router today. Second would be the Bosch 1617, and third the DeWalt 621. His reasons are:

The PC 890 is lightweight and comes in a blow molded case. The plunge base does not have a micro depth adjustment but the stationary base does. As an authorized factory repair center, he sees very few of these come back. It’s such a good router that he is surprised that DeWalt hasn’t discontinued them. There is no DeWalt corresponding router. Yes, he is disappointed that every tool is turning yellow.

He likes the Bosch 1617 and contrary to some reviews on Amazon, he hasn’t experienced any issues with the template guide bushing issue. It does not have a case. He believes, as do I that cases preserve tools.

Last was the DeWalt 621. It’s a good basic router based on the Elu design, and DeWalt purchased Elu of course.

He remembered the PC 7539 and stated that while it was discontinued, it did enjoy a brief upgrade for a year or so in the PC 8539 if you can find them. They are very rare. He can get some basic parts like brushes, switches, and other stuff unrelated to the armature.

I’ll have to noodle this.

[Jim Becker]

My power tool store guy (yes I still shop at a brick and mortar store) recommends the Porter Cable 890 over any 1/2” router today. Second would be the Bosch 1617, and third the DeWalt 621. His reasons are:
...There is no DeWalt corresponding router.
DW 618 is the corresponding router for power and base selection. I'm not familiar enough with the PC 890 to know any specific differences in features, however. I've been very pleased with the DW 618 thee-base kit, although I mostly use that router with the fixed base for lower-center-of-gravity when that's preferable. I have OF1400 and OF1010 routers for plunge use.

[BOB OLINGER]

Tom,

I had a Porter Cable originally purchased in the '70's that died. I took it to my local electric motor repair shop. They said the older ones are worth rewinding/repair. So, I oped for that and glad I did. I'm not saying it's cheaper, but just another option (that worked for me).

[Robert Hazelwood]

I can comment on the Bosch 1617. It's a good router, very smooth, plenty of power. The "quick change" template adapter system is extremely goofy IMO, I just removed the factory baseplate from the plunge base and replaced it with a generic acrylic base plate that accepts PC bushings directly.

The other thing is that the plunge base only rides on one rod. There are two rods, but only the side with the depth stop has an actual bushing for the rod, the other side just has an O-ring and the rod on that side is really just there to align the plunge spring. So there is a bit of play when the plunge lever is depressed, maybe 1/16" at the tip of the router bit. The play is taken out when you release the plunge lever.

Because the play is taken out when the lever is let go, for most tasks you can still do accurate work with it. But if you are routing a recess, the slop during the plunge stroke tends to cause the bit to go a hair deeper than the depth setting, making an indention where you plunge. If the bottom of the recess is a show surface then you have a lot of awkward sanding to do. That's not a common situation but it did happen to me.

The Bosch is not alone in this, my DW611 is similar. I think most of the modular motor and separate base style routers have the single bushing setup and so I'd be surprised if they didn't have similar looseness with the plunge lever depressed. Dedicated plunge routers seem to have more robust plunge rod setups, for example the DW625 definitely has two guide rods with bushings on both. The DW621 only has one bushing, but its on an extra large diameter rod (it's also a dust extraction tube) so would promise better rigidity. The Makita RP 2301 has two rods with a linear bearing on each (vs bronze bushings in the others). Except for the DW621 these are all large routers.

I had originally figured that the modular routers made dedicated plungers obsolete, but for certain tasks I think a dedicated plunger should be a little more accurate.

[jack duren]

Thomas , have you considered looking for another PC 7529 or 8529 on eBay or Craigslist ? I see them from time to time , often less than $100.

Bosch made a similar router labeled B1450 and 1613. They have the same depth adjustment knob as the subject router. I'm not positive but the 1613 may have been discontinued too. All take the PC bushings with the adapter ring. I have both routers with both guide bush setups and the PC is just a much smoother and refined tool. However , the Bosch is much tougher and the bayonet bushing system is easier, faster and better for changing them out.

I have the 1450,1614 and 1613 and I think they have all been discontinued. ....

[ChrisA Edwards]

I have the PC890 with both the fixed and plunge base. The dust collection is very good with the plunge base.

[Mike Henderson]

I have the PC-890 and the Bosch 1617. Both are good routers. For most of my work now, I use the Dewalt 611 (the trim router) unless I really need to take a lot off.

Mike