When To Replace Router Brushes - Router Forums
 
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post #1 of 10 (permalink) Old 01-08-2015, 06:56 PM Thread Starter
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Default When To Replace Router Brushes

How do you when to replace a router's brushes? The reason I ask is I can see some sparking inside the upper part of my router. I mostly use it in a table and can't see the motor during operation but recently I have been using it out of the table and noticed the sparks.
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post #2 of 10 (permalink) Old 01-08-2015, 07:56 PM
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Hi Jim,

I have seen some comments that indicate that the odd sparking is not a problem.

When the brushes are worn, I believe, you will get erratic behavior from the router.

So far, through limited use, I have not had to replace the brushes in any of my routers.

When I installed the MuscleChuck on my Triton TRA001, I removed the brushes while removing the old collet.

I had this router for some years and the brushes were hardly worn.

Others may have varied results...

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post #3 of 10 (permalink) Old 01-08-2015, 08:18 PM
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Like James says, alittle sparking is normal. If the router is running okay I wouldn't worry about it.

Someone I consider a master woodworker once told me that a master woodworker is not someone who never makes mistakes. He is someone who is able to cover them up so that no one can tell.
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post #4 of 10 (permalink) Old 01-08-2015, 09:43 PM Thread Starter
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Thank You. My router is running fine so I'll just keep on routing.
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post #5 of 10 (permalink) Old 01-09-2015, 09:17 AM
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If you can get to them reasonably easy. Look to see if they are getting too short. I would say that 3/16 - 1/4" is the minimum for routers. Change them when they get this short or shorter. If you don't change them several things can happen.

1. The spring tension behind them gets less as they wear, causing more arcing at the commutator.

2. The spring can come into contact with the armature and will likely burn out both.

3. A very short brush in it's slide is easily twwisted out of the slide by the rotating armature. This will break the brush, the slide, and likely the armature.

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post #6 of 10 (permalink) Old 01-09-2015, 10:39 AM
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It would not hurt to change the router brushes after a few years of good use and consider it router maintenance. An inexpensive way to keep your router in top working condition just like any other tool or anything else we own.

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post #7 of 10 (permalink) Old 01-09-2015, 11:23 AM Thread Starter
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Default Router Brushes

I have a DeWalt router, DW618. Manual says to have brushes replaced by a repair shop. Can I do this myself or are special tools or know-how required? Also, will I be able to obtain the correct brushes? I needed brushes for my miter saw and had a hard time finding a source.
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post #8 of 10 (permalink) Old 01-10-2015, 11:07 AM
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Quote:
Originally Posted by JIMMIEM View Post
I have a DeWalt router, DW618. Manual says to have brushes replaced by a repair shop. Can I do this myself or are special tools or know-how required? Also, will I be able to obtain the correct brushes? I needed brushes for my miter saw and had a hard time finding a source.
I've replaced brushes, armatures and switches on tools in the past and it is not difficult. They way I view it is the work done in repair shops is done by people with a bit of knowledge and any of us are capable of learning the same stuff.
the Dewalt repair center will most likely sell you the brushes.

“Each step of every Wood Art project I design and build is considered my masterpiece… because I want the finished product to reflect the quality and creativeness of my work. I study each piece to get ideas and details that will evolve in my future creations.
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post #9 of 10 (permalink) Old 01-10-2015, 11:25 AM
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Brushes for tools that you can't buy from the tool manufacturer or ereplacements.com might be found in a local better hardware store. They carry assorted sizes of common brushes. If they don't have the exact size, one is likely close and you can file or grind it to fit. Brushes are pressed carbon and they cut/grind easily, although a bit messy. Buy the right ones if you can, but consider this as a second possible source.

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post #10 of 10 (permalink) Old 01-10-2015, 06:26 PM
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Quote:
Originally Posted by GregLittleWoodworks View Post
It would not hurt to change the router brushes after a few years of good use and consider it router maintenance. An inexpensive way to keep your router in top working condition just like any other tool or anything else we own.

Good point, Greg.

(especially for my Makita 3600BR, which I believe is fairly old....)

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