Gee now that I know what you are trying to do I'm going to say I wouldn't use a router for all of it.... boy am I going to be in trouble here at a router forum but I just happen to know some people who make large signs doing very much what it sounds like you want to do. They have trees, sky, water, and the like all at different contures then paint them up and they come out great!
Now they don't use plywood but rather redwood... they glue up panels to the size they need but that doesn't say you can or can't use plywood, you can test that out. They also use 2 x stock so some of the removed material is an inch or so deep.
They also don't use a router except for when they need flat areas and they cut that first while the wood is still flat. The smaller "signs" they do horizontal but for the larger pieces they go almost vertical. (A lot of that is to keep the work surface from being covered in chips.) They use an angle grinder with a wheel that has what looks like chainsaw chain on it. I don't know what the proper term for these are but check:
http://www.amazon.com/gp/product/B00...lance&n=228013
They then use an angle grinder/sander to smooth things out. You can also get flapper sanding attachments for smaller indents and areas.
Now back to routers, and yes it is still a good idea to get a router.
The limiting factor on hand held routers is that you can not use very large bits (unsafe to do), these larger bits are what requires the extra power. If you attempt to take too deep a cut again it is unsafe... forceing the cut will wear out the bits very fast and that is also unsafe. The result is that the bigger is better doesn't apply. When I do signs I tend to go to my smaller trimmer routers and would never dream of using my 3-1/2 hp one.
Some routers are used in cnc machines and go 24 7 minus time for bit and workpiece changes. They get hot and at some point wear out and require repair, I have no idea how many hours that would be but yes some routers can take the heat. You will have to at least blow out the dust and keep it clean and replace the brushes as needed. Bearing are sealed but dust can wick out the lube so they don't last forever. You're right that most home users don't keep them on for extended times. I remember seeing a table once put most popular shop tools at one hour of operation for 20 hours of shop time.... ( I have seen cnc router mounts selling on ebay for Porter Cable and Hitachi so it is be assumed those two at least are used for that purpose.)
I have also seen those grinders with chainsaw blade used to carve all sorts of things and really remove material fast. Make sure you also read the reviews as they can also do fingers if the guard is not in the right place... or so the story goes.
Ed
__________________
Sometimes you get, and sometimes you get got.
Last edited by reible; 07-15-2006 at 12:20 AM.
|