DeWalt Fixed Base / Plunge Router Combo Kit

As someone who frequently tackles a variety of woodworking projects, I've had the pleasure of testing out DeWalt's Fixed Base / Plunge Router Combo Kit (DW616PK). This router has a lot of promise on paper, boasting a multitude of features that cater to both novice and experienced woodworkers. After using it on several projects, I've gathered some insights that could help you decide if this is the right tool for you.

Unboxing and Initial Impressions

Straight out of the box, the router feels robust and well-constructed. DeWalt's signature yellow and black color scheme adorns the durable die-cast aluminum base and motor housing, giving it a professional look. One of the first things I noticed was the rubber overmolded handles, which are designed for enhanced comfort and control. These handles are quite comfortable to hold, although I did experience some hand cramping during extended use, likely due to their ball-shaped design.

Power and Performance

The router is powered by a 1-3/4 hp motor with an 11.0 amp rating, which is more than sufficient for most hardwood routing tasks. I found it to be powerful enough to handle everything from simple edge trims to more complex dado cuts. The motor isn't overly noisy, which is a pleasant surprise, especially when working in a smaller workshop.

One feature that stood out is the micro-fine depth adjustment on the plunge base. It allows for precise depth settings, which is crucial for detailed woodworking. However, I did find the depth adjustment wheel on the plunge base to be somewhat cumbersome. The stop pin interferes with the screw on the wheel, making it difficult to achieve the desired setting without some fuss.

Usability and Ergonomics

Switching between the fixed and plunge bases is relatively straightforward, thanks to the quick release motor latches. This versatility is one of the router's strong points, allowing you to tackle a broader range of projects without needing multiple tools. The flat top design also makes bit changes easier, though the lack of a spindle lock means you'll need two wrenches to loosen the collet. This isn't a deal-breaker, but it is an inconvenience.

The tool-free steel motor cam lock is a nice touch, allowing for quick depth and base adjustments. However, accessing the spindle nut when using the fixed base can be a bit tricky, especially given the wide wrench supplied with the router. It’s worth noting that the router comes with both 1/2" and 1/4" collets, offering flexibility in bit selection. Unfortunately, the 1/4" collet adapter didn’t perform as well as expected, so I would recommend sourcing a higher quality adapter if you plan to use 1/4" bits frequently.

Dust Collection and Maintenance

The through-the-column dust collection system is effective at capturing dust, which is essential for maintaining a clean workspace and prolonging the life of the tool. The detachable cord set is another practical feature, making it easier to service and store the router. However, the router’s carrying case leaves much to be desired. It’s bulky and lacks compartments for bits, wrenches, and other accessories, which can make organization a bit of a hassle.

Areas for Improvement

Despite its many strengths, the router does have some notable drawbacks. The toggle power switch is awkwardly placed for handheld use, making it difficult to turn off the router without losing control, especially at the end of a cut. This could be a safety concern, particularly for those who are new to using routers.

Another issue is the plunge mechanism, which can be jerky if pressure is applied unevenly. This is something that can be managed with practice, but it does detract from the overall smoothness of operation. Additionally, the router tends to run hot after a few minutes of use, which could be a concern for extended projects.

Final Thoughts and Recommendation

Overall, the DeWalt Fixed Base / Plunge Router Combo Kit is a solid performer with a few areas that could use improvement. Its power and versatility make it a valuable addition to any woodworking toolkit, and the build quality is generally impressive. However, the design flaws, particularly with the plunge base and the power switch, do require some workarounds.

Would I recommend this router? Yes, with some reservations. If you’re looking for a versatile, powerful router that can handle a variety of tasks and you’re willing to overlook some ergonomic and design issues, this DeWalt router is a good choice. However, if ease of use and flawless design are your top priorities, you might want to consider other options or be prepared to make some modifications.