Cliff Posted November 20, 2015 Report Share Posted November 20, 2015 (edited) So I had an interesting night. Gather 'round all, for noob woodworker storytime..I have a DW621 router. picked it up used on ebay for about $150. I've used it once before, back when I first started my smoker cart project. Tonight I put it on a Jasper Circle Jig and started cutting. First pass through, the bit falls out. Figured I didn't tighten it enough. I keep going around, things are going well. I am almost through, maybe starting my last pass and I notice there is no more resistance. The bit fell out again. So I try to put it back in and it is not going well. Then I notice the bit looks a little weird on the end. I am pretty sure the bit broke off. See picture-This sucks, because it's a Whiteside bit and I've never used it before. I couldn't find the end of it anywhere. I have a regular straight router bit that is the same size so I can continue on. So I loosened the collet, and put the bit in but it doesn't seem to go very deep. I loosened the collet more, and it won't go any further. That's strange because it's removable. It should easily come off. Then I notice this-I'm going to assume that this wasn't cracked when I started but I honestly can't say for sure. So my thoughts on what went wrong - 1. I tightened the collet too much because the bit fell out (when in reality, it may have broke.) and I wanted to make sure it didn't do it again. That may have cracked it. Or I was turning it the wrong way when I thought I was loosening it and same thing happened, too tight - breaks. 2. I went deeper in the wood than I thought and that caused the bit to break.3. I didn't remember until a few mins ago that this is a variable speed router and it was set to the slowest speed for 1/2" collet, 1/2" spiral up cut bit that I used a while back. 4. The router came busted and I didn't know it. Anyone have thoughts?I am going to start shopping routers. I have two choices.. get a router for the router table and remove the DW621 that came with it (yeah, a second one!) and use that as my regular plunge. Or buy a new plunge router. Both options give me some flexibility. I can get one of those routers that you can adjust and take bits out from the top for the table. The only real thing I have to worry about is price (no Festool!) and if I buy it for outside the table, I need it to fit the Jasper Circle Jig. Oh - and a third, it may have to come from Home Depot. So I'll take your recommendations if you have any - but I will probably search on here cause I'm sure that is a topic that has been brought up many times. I'm more curious if anyone has had a router go down in flames like this! Edited November 20, 2015 by Cliff spelling Quote Link to comment Share on other sites More sharing options...
Al Capwn Posted November 20, 2015 Report Share Posted November 20, 2015 See if there is a recall/known defect on the unit. I had a Black & Decker ROS that the bottom literally exploded; turns out there was a recall. Turned it into the service center and they cut me a check on the spot, even though the unit was a couple years old. Sometimes recalls/known defects extend the warranty of the unit, so never hurts to check and see what the manufacturer can do for you first. 1 Quote Link to comment Share on other sites More sharing options...
davewyo Posted November 20, 2015 Report Share Posted November 20, 2015 Looks like you could just repair it yourself. I'm not sure of the exact type but check here for parts. Quote Link to comment Share on other sites More sharing options...
wtnhighlander Posted November 20, 2015 Report Share Posted November 20, 2015 That looks like the plate that retains the output shaft bearing..If you DIY it, I would replace the bearing, too. Quote Link to comment Share on other sites More sharing options...
Cliff Posted November 20, 2015 Author Report Share Posted November 20, 2015 Yeah i located the parts and diagram last night but I'm not sure I will do it. I'm not a mechanical dude. Looking at the diagram I have trouble even telling which part it is that I need to buy.However, if I do, I think I'll do it just to have a 3rd router. I think I've decided on getting a Triton 3.25 HP for the table and using the other dw621 as my router for the time being. Maybe, if I fix the other router I can just keep a different size collet in each. I'm honestly not impressed with the 621. Seems a pain in the ass to tighten down/loosen. The plunge action is jerky too. Might just be the one though. Quote Link to comment Share on other sites More sharing options...
TerryMcK Posted November 20, 2015 Report Share Posted November 20, 2015 There probably is a Dewalt service centre near you. They are owned by Stanley Black and Decker now so there may be one of those in the vicinity. It won't be an expensive repair. 1 Quote Link to comment Share on other sites More sharing options...
Eric. Posted November 20, 2015 Report Share Posted November 20, 2015 Might as well fix the bearing in the jointer while you're working on the router...otherwise you're gonna have a huge paperweight to go with your small one. Seriously...you should fix the jointer before it gets worse. Leaving a bad motor bearing can lead to a bad motor...that's gonna cost you considerably more to repair.I'm assuming your step-dad addressed the issue with the pulley wanting to slip off the shaft? How did he remedy that, out of curiosity? 1 Quote Link to comment Share on other sites More sharing options...
Cliff Posted November 20, 2015 Author Report Share Posted November 20, 2015 Great advice Terry! I didn't think of that. Of course the page for Dewalt Service Centers went down just as I input my zip code.. booo Might as well fix the bearing in the jointer while you're working on the router...otherwise you're gonna have a huge paperweight to go with your small one. Seriously...you should fix the jointer before it gets worse. Leaving a bad motor bearing can lead to a bad motor...that's gonna cost you considerably more to repair.I'm assuming your step-dad addressed the issue with the pulley wanting to slip off the shaft? How did he remedy that, out of curiosity?Oh I will fix it. I just want to finish this one project because it's been since May and I'm going to choke someone out if it isn't out of my way soon. At this point I've literally flattened 5 boards and I may be done with it until I start the next project. Not sure yet. So it might be nearing a good time to get that bearing replaced.I have no idea.. but the pulley seems to work. At least, it hasn't slipped off yet. Quote Link to comment Share on other sites More sharing options...
Eric. Posted November 20, 2015 Report Share Posted November 20, 2015 I had a buddy in college who put 200K miles on a Ford Escort without changing the oil once. I guess some guys just get lucky. I hope you're one of those guys, because you're pressing your luck. 1 Quote Link to comment Share on other sites More sharing options...
Cliff Posted November 20, 2015 Author Report Share Posted November 20, 2015 I had a buddy in college who put 200K miles on a Ford Escort without changing the oil once. I guess some guys just get lucky. I hope you're one of those guys, because you're pressing your luck. Well I don't even know how its possible to do that to a car. Holy crap. Meanwhile.. in jointer land.. limited use, as in the amount I used it so far - roughly 30 minutes is unlikely to cause a catastrophe. My goal is to get past this Christmas crap and get the work done on it. I still plan on being in mostly shop upgrade mode more than anything for the next few months so I may not need it again until March-ish. So I am not in a huge rush to get the bearings sorted out. Not only that.. but the way I have it set up right now, the only way I can have it set up - means I can only joint with the garage door open. That will soon be a very unpleasant prospect. So getting a flat floor and warm shop are still my priority over any other projects which means I won't be needing it for a bit 1 Quote Link to comment Share on other sites More sharing options...
bgreenb Posted November 20, 2015 Report Share Posted November 20, 2015 3. I didn't remember until a few mins ago that this is a variable speed router and it was set to the slowest speed for 1/2" collet, 1/2" spiral up cut bit that I used a while back. Not much to add beyond what everyone else said, but I wanted to address this point. Did you check the recommended speed setting for a 1/2" diameter bit? I would be absolutely shocked if it required the slowest speed on the router. In fact I'd be surprised if it required anything less than the highest speed. Quote Link to comment Share on other sites More sharing options...
Cliff Posted November 20, 2015 Author Report Share Posted November 20, 2015 Not much to add beyond what everyone else said, but I wanted to address this point. Did you check the recommended speed setting for a 1/2" diameter bit? I would be absolutely shocked if it required the slowest speed on the router. In fact I'd be surprised if it required anything less than the highest speed. I don't remember. I do think I looked up what speed to set it to. But the 1/2" bit wasn't what broke all to hell. It was a 1/4" bit, I definitely didn't adjust the router back up to the highest speed on it. Quote Link to comment Share on other sites More sharing options...
bgreenb Posted November 20, 2015 Report Share Posted November 20, 2015 I don't remember. I do think I looked up what speed to set it to. But the 1/2" bit wasn't what broke all to hell. It was a 1/4" bit, I definitely didn't adjust the router back up to the highest speed on it.Sure, I understand - but I'm just saying that you should re-check that 1/2" bit. Again, I would be very surprised if you needed to have it on the slow setting. Generally bits < 1" should be run at full speed. Quote Link to comment Share on other sites More sharing options...
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