Features and working of a D-handle router

The D-handle router has a cylinder-like body that contains the motor. A collet, which is a hexagonal holder, is located at the top end of the router. This is the component that firmly holds the tool bit in place. The collet can be tightened or loosened with a wrench. The bit protrudes out through a circular base plate.

The bit is one of the most important parts of the router, which actually performs the task required of the router. Router bits are of varied types depending on the task to be performed. Based on construction, they are broadly classified as either high-speed steel bits or carbide tipped bits. Further, the bits can be grouped into three categories; edge bits, non-edge bits, and anti-kickback bits. Edge bits are normally used in edge molding and incorporate a small wheel bearing apparatus, forming a fence against the work surface. Non-edge bits need an exclusive fence, connected to either the work or the router itself. Anti-kickback bits incorporate a packing below the edge of bit to prevent too-deep a gash into the work piece, causing a kickback. Bits are also differentiated by their shank diameter, varying between half inch, 12 mm, 10 mm, 3/8 inch, 8 mm, quarter inch, and 6 mm. It is necessary for the bit shank and the collet sizes to match. A rigid flat top ensures stability when changing bits.

Routers are generally of two types; plunge based and fixed based. Plunge based routers work by connecting the cutting bit with the work surface after the motor is turned on. Fixed based routers require the cut depth to be decided before the actual task is initiated.

The body of the router is generally constructed of magnesium to provide for a resilient and lightweight tool. The templet guide can be changed quickly with a tool-free templet guide adaptor. For enhanced accuracy, the precision centering design ensures that the bit is centered, which is a useful feature when a task requires multiple passes, such as jig cutting. The depth can be controlled through the coarse and microfine bit depth adjustment facility. An industrial cam lock doubles up to facilitate depth adjustment and motor detachment.

The average router uses an 11 amp, 1-3/4 horsepower motor. The D handle enables the user to control the tool easily and an auxiliary handle provides further stability. The speed of the tool can be adjusted by the user, which can vary from around 8000 revolutions per minute (rpm) to around 24,000 rpm. An aluminum housing for the motor increases durability.

What to look for in a D-handle router

A D-handle router is usually provided with an ergonomically contoured soft D handle to enhance comfort and reduce fatigue during intense prolonged usage. The palm grip side handle enables two handed operation of the tool. To accommodate even larger bits, the tool may have a larger center hole. A lock-on button keeps the tools operational continuously. The design of the center hole provides a clear line of sight for the user, enhancing speed and accuracy.

As with any tool having a motor and so many vibrating parts, there is bound to be operational noise which could be detrimental to the user’s ears in the long run. The D-handle router should minimize the noise levels to around 81 decibels, along with lower vibrations. To increase efficiency, the tool is provided with a soft start feature resulting in quick issueless start-up.

Reputed manufacturers of D-handle routers include Dewalt, Milwaukee, and Porter Cable.

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