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post #11 of 15 (permalink) Old 06-22-2018, 07:41 AM
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Aside from the actual need, it's call conniving although I don't see it as "given to or involved in conspiring to do something immoral, illegal, or harmful". I actually see it as a means to get what you need/want. After having looked up the actual word and using it for years, I'm wondering why I've used it so much. What you're doing "justifies" by means of being more safe and not overtaxing a lesser tool possible causing damage and unsafe conditions. I have two main routers, the Bosch 1617EVS and the Colt, which should handle my needs with the proper bits and knowledge. Cutting away the bulk of the waste as advised is the safest and best approach before putting the router bit to cleanup the edge. But it's important to realize that size and type of bit along with motor HP is only a part of the issue. How safely you can actually remove the amount of wood including the type of wood as explained is critical to safety as well. Smaller bits are more susceptible to breakage if forced or used improperly. The quality of the bit makes a big difference as well. I snapped a 1/4" straight bit just trying to slot 1/4" hardboard by going too fast (feeding the wood faster) and trying to take the full cut in one pass. I mostly blame it on the bit itself because of its quality but technique played a role as well.

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post #12 of 15 (permalink) Old 06-22-2018, 08:40 AM
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Another way is to cut it in several passes at increasing depths. In this case a router bushing rather than a bearing bit will work better. Ride the bushing along the template and increase the depth of cut no more than about 1/4" per pass. This should avoid the need to pre-cut with a saw to within 1/8" of your final dimension.


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post #13 of 15 (permalink) Old 06-22-2018, 08:44 AM
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Originally Posted by Matt Hickman View Post

The specific problem I am having is I have to go very slow when cutting patterns otherwise my router stops cutting and I have to back off and let the router speed back up then cut some more.

Here are the details of what I am trying to do.

I am cutting out Nativity scenes in 23/32 ply, my router is a Kobalt portable router with 2.5hp, I am using a pattern router bit that has a 1/2" shank and has a 2" cutting depth. The bit is relatively new so it is still sharp. It is a straight flute bit not a spiral bit.

The bit is cutting the full width so I am taking 3/4" wide cuts almost the entire way around the pattern.


Should I get a Triton 3 1/4 HP router (I am trying to find a way to justify this so any answers that can lead to this will be great)

Upgrade to Spiral top bearing flush cut bits

Trim my pattern so only 1/4 " is needed to be cut off

Other solutions?


1. Make sure you have a dust chute on your router with a SHOPVAC sucking.
2. You do not need to cut the full depth. Rout about 1/4 deep. Then use a jigsaw to saw out pattern leaving 1/8" to 1/4" for the router to trim later.
3. Remove the jig. Use a pattern bit to flush-trim the pattern bearing following the already routed pattern.

A 3 1/4 to 3 1/2 HP Router would be better if you do a lot of such jobs.

Good brands include (not in any order of preference):-
1. Triton
2. Bosch
3. Dewalt
4. Hitachi
5. Markita
But buy only if a DUST CHUTE is included or can be optionally purchased at the same time.

Best Regards


"The gift of God is eternal life thru Jesus Christ our Lord"
Reuel - means "God's friend" (Heb)
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post #14 of 15 (permalink) Old 07-11-2018, 11:02 PM
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Another scenario is the power cord you are using is too long and you have a significant power loss. How long of an extension cord are you using.
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post #15 of 15 (permalink) Old 07-11-2018, 11:12 PM
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Originally Posted by Bradford Hooper View Post
Another scenario is the power cord you are using is too long and you have a significant power loss. How long of an extension cord are you using.
too light of a gauge wire in an extension cord will do it too...

This would have been the week that I'd have finished chewing thru the restraints...
If only new layers hadn't been added....

Forget the primal scream, just ROAR!!!
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