All Replies on Dewalt dw 621 router stiff

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Dewalt dw 621 router stiff

by lennyk
posted 08-08-2016 10:30 AM

3 replies so far

View JBrow's profile


1368 posts in 1725 days

#1 posted 08-09-2016 02:19 AM


When my DW621 plunge router started giving me troubles I replaced it with a new DW621. Upon removing the new DW621 from the box I found the same issue; the plunge mechanism would stick when the trying to plunge the router from its home position making it difficult to use. After a little work, the plunge mechanism now works fairly smoothly, but still has just a little (very slight) stick once in a while.

I first used acetone to thoroughly clean the plunge columns. Once cleaned, the router was turned upside down and low viscosity sewing machine oil was applied all around the plunge rods. Then base of the still upside down router was worked up and down, trying to spread out the oil and work it into the plunge column housings. It took quite a few times but it eventually the stick was mostly overcome. After the plunging mechanism loosened up, I wiped excess oil from the plunge column with a paper towel. The router can now be safely used since plunging during operation is easily done. However, after it has set unused and I pull it out, I find that there is a slight resistance to the first plunge, but thereafter it operates smoothly. I figure the more it is used, the more smoothly it will operate.

Over time I expect that the plunge mechanism will stiffen up due to dirt and dust; it did on the old DW621. I found that cleaning and wiping the plunge columns and re-applying oil, working it into the plunge column housings, freed it up again.

If you have had the router apart my other thought is that the plunge depth lock mechanism may not be installed quite right.

View lennyk's profile


34 posts in 1637 days

#2 posted 08-09-2016 09:56 AM

thanks will try that, I wonder if the spring could also be taken out and modified to be a little less tension.

View JBrow's profile


1368 posts in 1725 days

#3 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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