DeWalt 2 HP EVS Plunge Router

Why this mid‑size plunge router has been getting the most work in my shop

Some tools gradually earn trust because they simply disappear while you’re working. That’s been my experience with the DW621. It’s a compact, dedicated plunge router that puts precision and dust control front and center, and over the past few months it’s become my go-to for everything from hinge mortises to stopped dadoes and template work.

Setup, build, and first impressions

Out of the box, the DW621 feels purpose-built rather than modular. At around 9 lb, it’s stout but not unwieldy, with a narrow footprint that’s easy to plant on an edge or balance on a jig. The machining is tidy. The plunge posts run on phosphor bronze bushings and glide straight without wiggle, and the one-piece motor shaft/spindle gives a reassuring sense of alignment when you square a bit to the base.

The router ships with both 1/4" and 1/2" collets, a spindle wrench, and an adapter plate for standard template guide bushings. There’s no edge guide in the box in my kit, which is worth noting if you rely on one.

Power and speed control

This is a 10-amp, electronically controlled, soft-start motor with a speed range of 8,000–24,000 rpm. The soft start is gentle without feeling sluggish; the bit comes up to speed smoothly, so the tool doesn’t torque in your hands at start-up. More importantly, the electronic control holds speed well under typical load. When plunging 1/2" mortises in hard maple or trenching 3/4" plywood with a 1/2" spiral bit, the pitch doesn’t sag and you don’t get that chatter that shows up when a router loses rpm mid-cut. For heavy, single-pass cuts with very large panel-raising bits, you’ll still want a bigger router, but for real-world handheld work this motor is well matched.

The variable-speed dial is easy to reach without looking, and the range gives you the flexibility to slow down for larger cutters and crank up for small trim bits.

Plunge mechanism and depth setting

What sets this router apart for me is the plunge and depth system. The rack-and-pinion adjuster is precise and predictable, and the micro-fine adjustment lets you sneak up on depth in genuinely tiny increments. The spec calls out 1/256" micro-adjust, and in practice I can dial in a hinge leaf recess until it’s dead flush without fuss.

The plunge stroke is 2-1/8", which covers typical mortising and through-routing duties. The three-position turret stop is simple and positive. In a perfect world, I’d have one more hard stop for multi-depth tasks like stair-step dadoes, but three gets me through most setups. The plunge lock is placed where it makes sense—easy to nudge with your thumb as you lower in, and it holds firmly without requiring a gorilla grip.

Dust collection and visibility

Dust control is outstanding for a handheld router. The DW621 routes chips through a channel in one of the plunge columns and out to a vacuum port. With a shop vac attached, it captures the bulk of chips at the source, even when plunging. That has two benefits: less post-cut cleanup and a consistently clear view of the bit. On mortises and stopped grooves, where chips tend to pool in the cavity and obscure the layout line, the built-in extraction keeps the cut visible so I’m not pausing mid-pass to brush out debris.

A practical note: hose management matters. A supple, lightweight hose keeps the router from feeling tethered. With a standard 1-1/4" vac hose, the balance stays comfortable and the hose doesn’t try to tip the router off the work.

Noise-wise, it’s not whisper-quiet, but the pitch is less shrill than some mid-size routers. Hearing protection remains a must.

Ergonomics and handling

The handles are rubber-coated and shaped to encourage a neutral wrist position. Balance is excellent; the center of gravity sits low over the base, which makes plunging straight down feel natural. The on/off control is integrated into one of the handles. It took me a couple of sessions to build the habit of that switch location, but once it’s in muscle memory, it’s a nice safety feature—I can start and stop the cut without shifting my grip.

The base size (roughly 4-5/16" by 6-1/4") strikes a good compromise between stability and access. On narrow parts—shelf edges, rail stock—the footprint is compact enough that the tool doesn’t feel teetery, and on jigs it seats evenly. There’s no built-in LED, but with the dust pulling chips away from the bit, sightlines are still good.

Vibration is low. The combination of bronze bushings and a stiff chassis gives the cut a calm feel, which makes it easier to stay on line, especially with long spirals or compression bits that can otherwise “walk” a router if the plunge columns are sloppy.

Bit changes and maintenance

Single-wrench bit changes are enabled by a spindle lock. The lock feels solid; it clicks home with an audible snap and doesn’t try to spring out under torque. There’s enough clearance to get the wrench squarely on the collet nut without grazing knuckles on the base. If you prefer two-wrench changes, that isn’t an option here, but I didn’t miss it.

The collets themselves grip cleanly and release without drama. As always, don’t bottom the bit; give it that small lift off the bottom of the collet for proper engagement.

Accuracy on real work

On a set of cabinet doors, I used the DW621 for hinge mortises with a 1/2" straight bit and a template guide. The micro adjust let me creep up on the exact leaf thickness so the hinges sat perfectly flush without sanding. On a bookcase carcass, I cut 3/4" stopped dadoes for shelves using a 3/8" upcut spiral; depth held true from end to end, and the wall finish was crisp enough that the shelves seated tight without cleanup passes.

Cutting patterns and inlays is where the included guide bushing adapter earns its keep. The sub-base is set up to accept the adapter, and standard template bushings then drop right in. Once installed, the plate stays put without introducing slop that could translate to chatter at the bit.

Trade-offs and limitations

• Power class: This is not a 3+ HP bruiser. It excels at handheld work with 1/2" shank bits and moderate cuts. For heavy, continuous raised-panel work or table mounting with big cutters, I reach for a larger motor.
• Turret stops: Three stops are useful, but a fourth would be handy for some stepped operations.
• Switch learning curve: The integrated on/off location is a thoughtful safety choice; it also took me a little time to stop reaching for a top-mounted toggle out of habit.
• Accessories: Depending on the package, you may not get an edge guide in the box. If edge routing is a staple for you, plan on adding one or building a shop-made fence.

Where it fits in a shop

As a dedicated plunge router, the DW621 complements, rather than replaces, a fixed-base setup. If you’re cutting mortises, stopped grooves, and template-routed parts with any regularity, the precision of the plunge system and the dust collection make day-to-day work smoother. For installers or anyone routing in finished spaces, the built-in extraction is a standout—less mess, less time draping plastic, better visibility on the line.

If your work leans heavily on router-table operations, this wouldn’t be my primary motor. It will run inverted in a pinch, but above-table height adjust and routing dust out through the column aren’t what it’s designed for.

Bottom line

The DW621 is a thoughtful, well-executed plunge router with three strengths that matter in real use: consistent electronic speed control, a precise and repeatable plunge/depth system, and best-in-class integrated dust collection. It’s balanced, easy to control, and built for accuracy rather than brute force.

Recommendation: I recommend this router to woodworkers who prioritize clean, precise handheld routing—mortises, stopped dadoes, template-guided work, and install jobs where dust control matters. It has the power and stability for 1/2" shank bits, the finesse to dial in sub-1/64" depth tweaks, and the ergonomics to make repeatable cuts without fighting the tool. If your primary need is a table-mounted powerhouse for large profile bits, look to a bigger motor. For everything else, this is a reliable, accurate, and tidy workhorse that earns its spot on the bench.