Router Accident - Trying to understand what happened

Darryl · Dec 30, 2008

I’m not new to woodworking, and I think I understand what happened, but looking for more thoughts.

I had a table router accident last week.
1. I would like to share it in hopes that it can stop someone else from repeating it.
2. I want to ensure that I understand what might have happened

I want to start out with the fact that I take great pride in being safe, as I think we all do. But I’m here to say that I misread what could happen. I now relate this as similar to a table saw kickback.

See attached pictures

I was doing a flush trim cut (.75” X 1.25” .5” Shaft flush trim bit) using ¼ inch hard board template. By the way, number 4 out of 4, so it was not the first one. The pine board was about 3 feet long with a 10 inch template at the right end of it. I was a couple inches into the cut, guiding the board with my right hand when all of a sudden the board flew to the right and the fingers of my left hand were in the router bit. The rest is history, including the ends of 2 fingers.

It’s been a week now and I think that I figured out what might have happened.
1. I think that the board somehow road up off of the bearing and then dug-in big time and fast
2. I think that the fingers of my left hand may not have been behind the board, but resting on top of it holding it down.
3. The board launched from left to right like a bullet, so fast that my left hand did not react, but instead went with the board to the bit. Just like a kick back on a table saw.

Does this sound like what may have happened?

Thanks in advance for your help

dovetail_65 · Dec 30, 2008

I bet you never do that again!

Were you trying to take off to much wood ? Taking more than than an 1/8" off is a no no.

What you propose may have happened. The best way to prevent that is to make your set up better. Like adding handles to hold to the template or workpiece. Then your hand would have been behind the wood and could not have slipped off the wood.

Even if the wood did slip off the template and grab the wood you need to think about where your hands would be if something like that happened and build the safety into the jig, fixture or or even the table you are using.

The pictures are great to show my kids to remind them why never to touch dads tools.

I have cut my finger tip off on a table saw. 100% my fault doing something stupid.

I can add some pictures as well, but I think yours tell the story well enough.

Not to be an ass, but this is 100% operator error as 99.9% of accidents are, IMHO.

I hope you heal fast.

NavyCharles24 · Jan 19, 2012

It's an old post but boy oh boy oh boy, this section has really reminded me, in a BIG WAY, to Read, Know and Understand how my Power Tools Operate. Your pictures are stunning to the point. Even 3+ years later. Thank you for the reminder.

bobj3 · Dec 30, 2008

DAM Darryl

I'm sorry to see you got nailed

They can get you in a heart beat

=======

Darryl said:
I’m not new to woodworking, and I think I understand what happened, but looking for more thoughts.

I had a table router accident last week.
1. I would like to share it in hopes that it can stop someone else from repeating it.
2. I want to ensure that I understand what might have happened

I want to start out with the fact that I take great pride in being safe, as I think we all do. But I’m here to say that I misread what could happen. I now relate this as similar to a table saw kickback.

See attached pictures

I was doing a flush trim cut (.75” X 1.25” .5” Shaft flush trim bit) using ¼ inch hard board template. By the way, number 4 out of 4, so it was not the first one. The pine board was about 3 feet long with a 10 inch template at the right end of it. I was a couple inches into the cut, guiding the board with my right hand when all of a sudden the board flew to the right and the fingers of my left hand were in the router bit. The rest is history, including the ends of 2 fingers.

It’s been a week now and I think that I figured out what might have happened.
1. I think that the board somehow road up off of the bearing and then dug-in big time and fast
2. I think that the fingers of my left hand may not have been behind the board, but resting on top of it holding it down.
3. The board launched from left to right like a bullet, so fast that my left hand did not react, but instead went with the board to the bit. Just like a kick back on a table saw.

Does this sound like what may have happened?

Thanks in advance for your help

Darryl · Dec 30, 2008

I was taking < 1/8 off. I guess I never thought the router could pull a board like that, but when you think about it, 3hp at 25K rpms, it sure can. It goes to show that you must always have an escape route for your fingers. A better setup next time for sure. I think chucking the bit in a hand-held pluge router and stationary work piece.

Thanks for the quick reply, how long did your healing take?

bobj3 · Dec 30, 2008

Hi Darryl

You and Allison now can chat about the same thing almost

she is on the forum almost every day

http://www.routerforums.com/41820-post6.html

=========

Bob N · Dec 30, 2008

Oh Man that has to hurt like all get out. I am sorry to read of your accident Darryl and hope things heal quickly. I know there is no sure fire way to prevent accidents, but it makes me understand why I use tools like my Grr...rippers so much. Next to the table saw, the router keeps my attention at attention.

Best of luck and thanks for sharing with us as a reminder.

dovetail_65 · Dec 30, 2008

I still feel it, I think about 6 months it took to totally grow a nail and everything, but I lost just the tip, you lost more. They sewed most of my tip back on. It was cut off halfway between the top and bottom of the finger nail. I think my tip grew back so well because my cut was straight. They just sewed it right back on the finger. The router probably cut your finger in a worse way were nothing could be used.

I feel bad for you, that hurts!

mailee · Dec 30, 2008

Sorry to hear of your accident Darryl. Do I take it from your posting that you only had one hand controlling the router? I always use both hands to control the router even if on the baseplate (as in sign routing) I always clamp the timber or if it is small enough use a router mat. I do hope it heals quickly for you and feel for your pain.

Excuse my ignorance I just re read the posting and it was on the router table, Sorry.

AxlMyk · Dec 30, 2008

Damn. That is terrible. It looks like the guide bearing is too far down.
Push blocks. That's what you need to use. I've made several of them for uses like that.
Hope your fingers heal well.

Bogydave · Dec 30, 2008

1st: Sorry about the accident. Hope a good recovery & no restricted finger usage.

2nd: Thanks for posting the accident.
Very good reminder to keep everyone on their toes that working with routers (as well as other tools) can be dangerous.
I'm new to routers so this is a real good "this can happen" scenario.

I made this for free hand cuts just cause I got nervous being close to the bits.
Got the idea from one of bj3 jigs.
Don't know if this would have helped, but maybe. (bottom pics)
http://www.routerforums.com/88918-post29.html

Again
Thanks & hope all heals well.

cbsjoez1935 · Dec 30, 2008

Darryl,
I am sorry to see that happen to anyone. When you say the piece pulled off to the right and your left hand was behind the piece, I think I might have a belated answer. From your pictures, it would appear that you were feeding the piece in the wrong direction. That is to say, the piece should have been on the left side of the router bit and you should have been feeding it from right to left. When in the table, the bit rotation is counter-clockwise. I would think you may have hit a knot and were actually doing what is called a "climb cut". With the bit in a pulling direction, it caused the piece to bounce off and pull you in. You did not say how you were feeding it and what I just said may not be the answer, but as Bob & Rick have said before "observe bit rotation". I hope your recovery is quick.
Joe Z.

Darryl · Dec 31, 2008

Hi Joe,
Thanks for the feedback, I was feeding it right to left against the bit rotation, so it was not a climb cut, I would not do those intentionally. I was only cutting the curved part. I know it may sound a little confusing, I started my cut about 10" from the right end.

Thanks for the good wishes
Darryl

Birchwood · Dec 31, 2008

Thank you thank you thank you for posting your experience. It will help the rest of us (I hope) pay CLOSE attention to what we are doing. I recognize those stiff black threads protruding from your finger stubs. Had a few of those myself now and again. It'll heal faster than you think. Sometimes a little sip of good bourbon will help.....after you have finished work of course.
Oh...none of the black threads were the result of a tool accident. I'm the original Captain Cautious when it comes to power tools.

bobj3 · Dec 31, 2008

Hi Birch

By the way how is your knife cut accident healing

======

jw2170 · Dec 31, 2008

Darryl,

Thanks for the post.

We should all be reminded every now and then of the danger of the tools we use.

Sorry that it had to be at your expense. get well soon.

Every time I approach the router table from now on I will picture the ends of your fingers.

James

Hamlin · Dec 31, 2008

Hi Darryl,

Sorry to hear of this accident. I hope that you heal quickly.

I have to agree with Joe Z. It sounds like feeding in the wrong direction. The following I suggest for everyone. Please consider a simple jig with a hold down clamp. There are some jigs on the market to handle such jobs.

I'd rather talk with you all than about you.

jjciesla · Dec 31, 2008

Damn, that's a hard hit! All my best in your healing process. This post will really get everyone thinking. Thanks for sharing.

dovetail_65 · Dec 31, 2008

Darn it my fingers hurt more and more every time I read this thread!

a1tomo · Dec 31, 2008

Such a terrible thing Daryl. I'm really sorry!

Perhaps I'm wrong, but truly believe most accidents happen when we get over confident or aren't fully involved in what we are doing. If you feel that the task you are doing is possibly dangerous, STOP and reconsider. Feelings are facts!

Be safe, Tom

Lemuzz · Jan 1, 2009

Were you using a flush trim or patern bit? I have been using a patern bit (well extended) and the bearing slips down the shank. and the work ruined. Maybe this was the case and your fingers were ruined too!

dovetail_65 · Jan 1, 2009

Gotta check that collar for tightness!

nzgeordie · Jan 1, 2009

Heck Darryl. That's just got to have hurt!!

How close have we all come to doing the same thing? Could it have been a change in direction of the wood grain? I experienced (almost) the same thing when routing some table legs with a pattern bit and didn't pay enough attention to the changing grain direction. Hope you heal soon, mate.

Darryl · Jan 2, 2009

I just went and checked the bearing and it had not slipped at all. I guess I have been looking for any reason other than operator error, this was one on the few cuts that I have made without using a jig or push block (grippers) and I knew my right hand was safe behind the bit holding the board.

That should have been an indicator to me, I felt that I had to hold the board with my hand, therefore I indirectly knew I was not enough control to use a push-pad gripper.

I never gave a thought to my left hand being in danger because it was over a foot away and getting further away. Had I been steadying the board with a gripper pad, I would still have all of my fingers. Notice in the 1st pic of my router table my blue & yellow gripper is sitting there. I have 4 of them, there's no excuse.

I hope that others who consider themselves safety conscious as I did, can learn that sometimes we get too complacent

Thank you all for the good wishes and kind thoughts, It’s been a crazy week for me Just talking about it on the forum helps.

Thanks Again, too all and Happy New Year
Darryl

dovetail_65 · Jan 2, 2009

You are doing right by working it out in your head.

But if the bearing slipped that is most probably still operator error for not checking it before you began.

How is the injury feeling today? Throbbing? On pain meds? I hope you get better fast.

Did you get right back on the horse or still waiting to turn that thing on?

When I cut my finger tip I used the table saw that night to get over it. Of course my wife gave me the business. I wanted to get the feeling of respect for the tool and not let fear creep in.

Darryl · Jan 2, 2009

I did a little cutting on the table saw, of course I was getting the business from my wife as soon as she heard it running.

Can do much of anything yet, I can only have my hand below my heart for short periods. I am off the pain killers as of yesterday. Type is really slow

Cedar · Jan 2, 2009

That is scarey!
So sorry that happened to you and hope your fingers heal quickly!
Thank you for sharing though,it is a great reminder to us all.
PJ

kefjens · Jan 2, 2009

Jimminy shikes!! Thanks for posting this to teach a newb like me to be very, very careful. I hope you heal quickly.

I think I will be adding a "bit rotation" reminder to the router table top since I'm so new to this art.

template tom · Jan 2, 2009

Accidents with the router

It is always sad when you hear of such tragic accidents when using the router and I only hope we can all learn a lesson from some Else's mishap.

Darryl
I hope you get well soon and it will mend and you can continue to enjoy your woodworking projects.

I think if we were to run a poll an how we had an accident with the router I am convinced that the router in the router table would head the poll as opposed to the hand held use using template guides

Recently I have devised a method of doing exactly what you were doing with the router where the fingers do not get near the cutter.( another one of my jigs to show that not all procedures should be done in the router table). I will not post it as I am sure I will get a negative response to the procedure but I am willing to forward to you by email on condition that you do not submit it to the forum.

One of the quotes I use regularly when discussing how a certain procedure could be carried out, and this is a typical example."Can it be done safely" and to this end, this is one of the reasons why I have continued to say, "maybe it would be better to make a simple Jig and template to produce the article with greater safety". I have included the method on my DVD with a number of other jigs and templates that enable me to produce articles or do procedures that are best done with the aid of template guides and the router in the plunge mode

All I can say is that members must consider the use of the template guides with the router in the plunge mode and not placed in the table as Bobj3 suggests in a previous posting.

Tom

RustyW · Jan 3, 2009

template tom said:
Recently I have devised a method of doing exactly what you were doing with the router where the fingers do not get near the cutter.( another one of my jigs to show that not all procedures should be done in the router table). I will not post it as I am sure I will get a negative response to the procedure but I am willing to forward to you by email on condition that you do not submit it to the forum.

Tom, I have learned a great deal about routing safely by trying your methods. If you have information that may save someones fingers, please don't hold back. Negative responses or not, I'd like to keep all mine.

Ice · Jan 3, 2009

Be careful

Hi Darryl,
So sorry about your accident, about 6 months ago i was routing a piece of maple about 24" long. Everything was going great until I got about half way through it and it just exploded. Splinters everywhere, I grabbed my hand that was holding the wood and was afraid to look at it for the longest time. Blood was dropping on the floor and i finally looked at it. I was not sure if I still had a thumb, that is what I was really scared of. I was lucky it was a fleshy wound but nothing time couldn't help. For the longest time I would not run a piece of wood through a machine with my bare hands but I am now getting back to my old ways of using my bare hands. Now I am scared again. I never could find out why the piece of maple exploded. Good luck, Joe

Darryl · Jan 3, 2009

Ice said:
Hi Darryl,
So sorry about your accident, about 6 months ago i was routing a piece of maple about 24" long. Everything was going great until I got about half way through it and it just exploded. Splinters everywhere, I grabbed my hand that was holding the wood and was afraid to look at it for the longest time. Blood was dropping on the floor and i finally looked at it. I was not sure if I still had a thumb, that is what I was really scared of. I was lucky it was a fleshy wound but nothing time couldn't help. For the longest time I would not run a piece of wood through a machine with my bare hands but I am now getting back to my old ways of using my bare hands. Now I am scared again. I never could find out why the piece of maple exploded. Good luck, Joe

Thanks Joe,
I know exactly how you felt. All of a sudden WOW! It curious, my wounds left very little blood for the damage it did.
I have some drawer fronts and raised panel doors to make. I get the stitches (the kids call them bugs) taken out next week. All the work I do for awhile will be with jigs etc.

Darryl

Router Accident - Trying to understand what happened

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