A router is one of the most versatile tools in the workshop of a woodworker. They have varied uses such as cutting patterns, duplicating shapes, trimming edges, laminating, making signs, cutting shapes and profiles into the edge of boards, amongst many others. Routers are compatible with an array of bits available, making them indispensable for most projects. Routers are broadly categorized in two types: plunge routers and fix base routers.

The key feature that sets plunge routers apart from fixed based routers is the plunge mechanism. Also, in a plunge router one can adjust the depth of cut while the router is turned on. Additionally, the depth stops allow the routers to plunge accurately to the appropriate depth while in use. Due to the plunge mechanism, these routers are heavier than fixed base routers. Plunge routers can also be used in projects where cutting mortises, dados, stopped groves, and incised letters are required.

Features and working of plunge routers

Plunge routers are powered by motors that are typically rated in horsepower (hp). Higher the horsepower, more powerful is the tool; however the weight is also higher. Generally, these plunge routers have of 2 to 3.50 hp motors. These horsepower ratings are assigned by the manufacturers themselves. Whenever, the tool has a power rating in amps, its performance is tested and assigned by Underwriter Laboratories (UL). The power rating varies from router to router and manufacturer to manufacturer. The motor generates a high torque by rotating at 20,000 to 30,000 revolutions per minute (rpm). The high rpm rate complements the small size of the bit.

The bits of the router are described by their shank size (the part of the bit that fits into the router). Typically, a router bit is available in three sizes: 1/4, 3/8, and 1/2 inch. The Electronic Variable Speed (EVS) technology allows the user to adjust the speed of the bit. Changing of the bit is the next concern of the operator. There are different ways of changing the bit of the plunge router; either using a single wrench along with a spindle lock, or using two matching wrenches. If the router has a spindle lock, then the user requires only one wrench to change the bit. In a router with a dual wrench, one wrench is used on the collet, whereas the other wrench fixes on to the top like a key and holds the shaft. This prevents the collet from spinning. Recently, there have been routers available in the market that does not require any tool while changing the bit.

Depending on the manufacturer, the placement and type of the router switch varies. Broadly there are two different types of switch styles: “Toggle Switches” and “Trigger Switches”. A trigger switch resembles the switch on a circular saw; whereas a toggle switch is similar to a light switch. In a trigger switch the router is ON only when the switch is pressed. For continuous application of the plunge router one can lock the switch in the ON position.
Plunge routers are often complimented with accessories such as jigs that help in making table legs, dovetail joints, and others. The edge guide keeps the router at a fixed distance from the work piece; therefore it is commonly used while routing a straight profile on a board. For inlay work, sign making, and pattern making, the router is fitted with a bushing. The router table enables the router to be inverted and can be used as a sharpener for making moldings and while working on small pieces.

What to look for in a plunge router

While making a decision on purchasing a plunge router, it is important to consider the project that the router is needed for, the amount of time that the router will be used, and the budget. Accordingly, there are three things that one should look for in a router: smart body, simplicity, and convenience while operating the tool. One should also check the power-to-weight ratio of the tool. From the wide range of routers available, it is advisable to select the router that is compatible with a 1/2 inch bit; since, these routers generally accept 1/4 inch bit sizes too. The plunge router with a special adapter or a different collet gives flexibility for expanding the bit selection. The plunge routers that are compatible with 1/4 inch bit sizes often do not offer this flexibility.

The other important factor is the quick bit changing system. A spindle lock system is preferable. Easy and accurate fence adjustment is the next feature to consider while purchasing a router. The tool should have a simple procedure for choosing the settings. The buyer should also be assured that minimal or no chiseling is required after the tool is used for mortising a hinge or cutting hardware.

The body of the tool should be safe, well laid out, and easily serviceable. Moreover, it is vital to see if the tool body feels comfortable in the user’s hands while in operation. Also, check the accessories packaged with the tool including the number of spare bits. The edge guide for the tool should be selected carefully. The seal-bearing guide is one of the better options. The visibility of the bit while in operation is important, to ensure precision of the work. This is mostly possible in plunge routers with a clear plastic base. However, the clear plastic base routers are not as durable as routers with a combination of a metal and plastic base. Some routers even have a work light, and/or a micro-adjustment system as an accessory that gives additional value to the product. Some of the plunge routers have the twist-and-lock system that enables the motor to slide up or down in the housing, allowing the user to adjust the base as required.

It is also important to consider the bit size and the types that the tool is compatible with. Routers with adjustable speed offer the additional advantage of controlling the bit while cutting intricate lines.

Some reputed manufacturers of plunge routers include Makita, DeWalt, TD Industrial, Porter Cable, and Bosch.

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