Routers
What is a router?
A router is among the most versatile portable woodworking tools you can own. It operates very much like a drill - its portable, housed motor drives a shaft and collet that turns a variety of bits at high speeds to shape and cut wood. A combination of speed and the number of bit flutes (typically two) makes the router a clean cutting tool. With the right bit, a router can plane edges, cut multi-curved mouldings, produce relief panels, rabbet and dovetail for professional joints, trim Formica and cut delicate grooves for professional inlay work.
What types of routers are available?
There are three main types of routers available:
1. Fixed base router.
The standard router is used to plane edges, cut curved mouldings, dovetail joints and grooves as well as make relief panels.
2. Plunge router.
A plunge router can be used like a standard router but that's not all. Its design allows accurate internal cuts, inlay work and mortising. Plunge routers usually have greater depth adjustment and more power for cuts of greater depth.
3. Laminate trimmer.
This is the router of choice for trimming laminates and veneers. Its smaller size gives you better control when trimming in more precarious spots and around edges. Most consumer model laminate trimmers only accept 1/4-inch bits.
How much do routers cost?
Like many other portable power tools, routers vary in price. The amount you spend on a router will depend greatly on the type of tool you choose and the specific features and benefits it offers.
What kind of bits are available?
Despite its many features, a router is basically just a motor if you don't own the accessories. Router bits are classified by: construction, size and function. Most router bits are classified into three different construction categories:
1. High-speed steel bits are designed for the person just getting started. These bits are economical, yet durable.
2. Standard carbide-tipped bits are durable and typically last much longer than steel bits.
3. Industrial bits have a heavy-duty, high-grade carbide tip and an integral shank. These bits are commonly used by serious and professional woodworkers.
Size classification relates to shank diameter. Common router-bit sizes are 1/4 inch and 1/2 inch. The 1/2-inch bits are generally recommended for heavy-duty applications. Classification by function focuses on the application to which the bit is best suited.
1. Straight bits are used for trimming edges, as in jointing operations, and grooving for dado and rabbet cuts.
2. End cutting bits cut at the bottom and the sides. They are used for fluting, grooving, carving, etc. End cutting bits are also used for plunge cuts.
3. Specialty bits are typically used for fine cabinet work and bear names that represent the types of cuts they make: rail and stile, panel raising, tongue and groove, drawer and box joint and dovetail.
4. Decorative edge-forming bits are guided by a pilot for fast edge-forming cuts. They are used for creating decorative mouldings, furniture or cabinet trim and picture frames.
What does a router pilot bit do?
An arbor-type bit with a pilot is excellent for quick, easy edge shaping of any workpiece edge that is either straight or curved, as much as or more than the radius of the bit to be used. The pilot prevents the bit from making too deep a cut. Holding the pilot firmly in contact with the workpiece edge throughout prevents the cut from becoming too shallow.
Which size biscuit should I use with my joiner?
Biscuits are made of compressed hardwood. They're approximately 5/32 inches. thick and are available in three conventional sizes: #0, #10 and #20. Here is what each biscuit size is most commonly used for:
Size #0 (5/8 x 1-13/16 inches): For hidden spline, mitres and butt joints used in the construction of small, intricate furniture.
Size #10 (13/16 x 2-1/16 inches): For edge joints, tabletops, mirror and picture frames and all furniture construction where a strong glue joint is required.
Size #20 (15/16 x 2-5/16 inches): For joining a leg to a rail assembly, a tabletop to its apron and other large furniture construction where alignment and strength are very important.
Is a router table worthwhile?
A router table will dramatically expand the type of cuts a router can perform. It converts a router into an excellent high-speed, bench-type wood shaper on which a wide array of intricate edge-shaping work can be performed, even on small workpieces, which are difficult to shape when guiding the router by hand. Here are some key benefits of router tables:
- When end-shaping a board that's too narrow to be guided by the fence, a mitre gauge is available to provide you with a firm grip.
- The table's grooved work surface helps prevent dust buildup that can prevent you from holding the piece flat.
- You can straighten and smooth edges to make perfect joints, or you can edge shape the whole or any part of a straight or curved workpiece edge.
- You can route through a workpiece to create slots or latticework designs.
- Extensions are available that attach onto the router table, increasing the size of your work area.
Purchasing Tips
Ask yourself these questions when choosing a router...
You can narrow down your router choices by asking yourself some basic questions. Your answers can help you choose the model that best meets your needs.
What type of projects are you planning?
Because plunge routers allow you to position the router and lower the bit accurately, they are a good choice for blind dadoes and similar cuts that don't stop at the edge of the workpiece. Fixed-base routers are a good choice for jobs that don't require adjustments to the depth of the cut. They are also a good choice for cutting rabbets and decorative facings on edges.
What types of cuts do you wish to make?
The type of cuts you plan to make will determine what type of router bits you need to use. Straight cutting bits are used for trimming and joining edges, mortise and tenon cuts, grooving for dado-type or rabbet-type cuts and the inlay of thin wood veneers. End cutting or groove-cutting bits are used for decorative grooves, fluting, freehand or carving. Decorative edge-forming bits are used for creating decorative mouldings, furniture/cabinet trim and picture frames. Specialty bits are used to create fine cabinetry such as panel raising, rail and stile, tongue and groove and laminate trimming.
What type of materials will you be working with?
Think about the materials you will be cutting. Plunge and fixed-base routers are generally used for wood. Laminate trimmers should be used for kitchen and bath countertop materials, laminates and veneers.
Consider these important router features...
Power. Most routers range from 8.5 amps to 15 amps. In general, more power allows for easier cuts. But keep in mind, more power also means a heavier router.
Variable speed settings. This feature matches different bit profiles, operator comfort level and the hardness of the material being cut. Larger bits typically require slower speeds to avoid burning the workpiece.
1/4 inch and 1/2 inch collets. Higher-end routers typically have 1/4 inch or 1/2 inch collets to accept a wider variety of bits.
Adjustable depth stops. The router can be preset to provide progressive depth settings for cuts requiring repetitive passes.
Handles. Most routers offer either D-handles or knob-style handles. User preference depends on comfort and the ability to control the tool. D-handles typically have a power switch under the index finger - a good safety feature when working with blind dadoes. Whatever handle-style you choose, it should not be an effort to hold and operate the router.
Shaft locking. This feature allows a single wrench change of bits and helps prevent accidental start-up during bit changes.
Built-in work light. Some fixed-base routers offer a built-in work light to increase the visibility of the work surface.
Dust extraction hookup. Because routers can produce a considerable amount of sawdust, look for a model that provides a dust-extraction hook-up (typically for a shop vacuum).
Don't forget the extras...
When purchasing a router, don't forget all the items that you may need. For proper operation of a router you will need:
- Miscellaneous router bits and attachments. For safe operation of a router you will need:
- Safety goggles or glasses. You may want to consider the following router accessories, as well:
- Router tables and table saw extensions, to add extra support for larger workpieces.
- Dovetailing kits, to provide a simple template for repetitious dovetail cuts.
- Edge guides, to aid in precise cuts, straight and along contours.
- A mortise and tenon fixture, to make consistent and repetitious straight, mitred and bevelled mortise and tenon joints.
- A biscuit system plate/edge-joiner kit, to turn your router into a biscuit machine.
- Sign kits, to make letters in various sizes.
- A work mat, to permit freehand routing without the interference of clamps.
- Router table-guide masters, to offer greater control over edge routing for small workpieces and difficult end-grain tasks and to adjust different workpiece thicknesses and widths.
- A foot-activated switch, to keep your hands free.
Product Maintenance and Cleaning
Having your router repaired
Check your sales receipt to find the date you purchased the router, then look in the owner's manual to see the length and details of the warranty. If you need service, call 1-800-4-MY-HOME® (1-800-469-4663) for the Sears Parts and Service location nearest you.
General Maintenance
- Inspect the router for frayed cords, loose or broken parts or switches and other obvious problems before each use. If damaged, have the tool serviced before you use it.
- Do not attempt to repair a cracked or broken part. This could result in a part which will no longer operate as designed, placing the user at risk.
- Follow the lubrication guidelines in the owner's operating manual.
- Keep any safety devices clean.
- Use only accessories that are recommended by the manufacturer for your particular router.
- Do not expose the router to rain or wet conditions.
- Keep the router's cord away from heat, oil, sharp edges and moving parts.
- Do not wrap the cord around the router for storage.
- Clean the unit using a damp cloth and mild detergent.
- Cover the router and store it in a dry place.
Product Safety
Before operating
- The best time to consider safety is before you purchase a router.
- Make sure you can physically handle the tool before purchasing.
- Read and understand the owner's operating manual. Learn where the controls are and what they do.
- Keep your work areas free of clutter and ensure they have adequate lighting.
- Do not remove or disable safety guards or devices.
- For best control, keep the router handles dry, clean and free from oil and grease.
- Make sure the thumbscrews that fasten the router base to the motor remain tight.
- When plugging a router into an outlet or connecting a router to an extension cord, be sure the power switch is in the "off" position.
- Do not carry a router by its cord.
While Operating
- Always wear the proper clothing and gear when operating the router. This includes safety glasses, ear protection, gloves, face shield, dust mask and appropriate footwear. Avoid wearing loose clothing and jewellery. If your hair is shoulder length or longer, tie it back.
- Keep all bystanders, children and pets clear of the work area.
- Know how to stop the router quickly, if needed.
- Use grounded extension cords and be careful to work away from the cord.
- Do not use the router in damp or wet locations.
- Never unplug a router by pulling on the cord.
- Do not use a router with a cracked or damaged cord.
- Never leave an idle router unattended.
- Only use the router for the job it was engineered to do.
- Be sure to turn off and unplug a router before changing accessories.
- Do not operate a router when you are fatigued or under the influence of drugs or alcohol.
- Do not operate power tools in the presence of flammable liquids, gases or dust. Some tools create sparks, which could cause a fire or explosion.