Reply by JBrow

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Posted on Dewalt dw 621 router stiff

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1368 posts in 1426 days

#1 posted 08-09-2016 12:29 PM


The only plunge spring I have removed is in the Hitachi router hanging in the router table, which is dedicated to the router table. I keep the DW621 for hand routing. I removed the both springs to make depth adjustment easier. Putting the Hitachi back together was a little tricky due to the plunge locking mechanism but in the end it went together fine. I would expect the DW621 would similarly come apart and go back together.

I would have a little concern about removing one of the plunge springs on a handheld router. My concern would be the ease and reliability of the router returning to the upper most home position. I figure this is safest position of the router bit when the machine is runner. When starting the router or if something bad happens while routing, one of the things I would want to count on is the router bit fully retracting. Another potential problem is whether the strength of one spring is sufficient to allow the plunge mechanism to function. The strength of the just one spring may be too weak to retract the router to its home position. The last potential problem is that a single spring could cause the plunge tubes to cant and jamb, resulting in unsmooth operation of the plunge mechanism. The only way I know how well the router will operate is to remove one of the springs and check.

If the DW621 plunge mechanism does not stick, but operates smooth; just that it requires a little too much downward force when routing mortises, then perhaps the tippy problem could be solved with a fixture or jig that broadens the platform on which the router sets. One type could clamp to the work piece while the other style could attached to the router. Here is one idea for a jig that attaches to the router from YouTube. I did not look, but I am sure there are other designs there also.

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