I have a straight router bit stuck in my Bosch 1615 plunge router. When I put the bit into the router, I pushed it all the way in until it hit the bottem before tightning the collet (I didn't know you shouldn't do that at the time). I have loosened the collet (even took the collet all the way off). I put a towell over the bit and pushed/pulled the bit different directions but the bit did not move or loosen. I very lightly tapped the bit with a small hammer but again the bit did not move or loosen. I do not want to tap the bit any harder because I do not want to damage the bearings or router in general. Please help me free my router for a new project!!!! Any ideas? Thanks, Jon.
My solution is to remove the nut, sleeve and bit from the router.
Take a look at where the spindle lock is on the router. Now, there are two flat surfaces on the armature. Get yourself a cheap, flat wrench that will fit those flat spots without disturbing the spindle lock.
Next, get a flat wrench that fits the collet nut. Now, position the spindle wrench, then the collet wrench. The collet nut will be lefty loosy and righty tighty. THat is, the nut should turn counter clockwise while looking at the bottom of the router while the base is pointing at the ceiling.
Undo the nut completely. It will be trapped between the bit and the collet but that's OK.
Take the collet parts over to a vice or find some way of supporting the shoulders of the _collet_. You want to support the collet while tapping with a hammer and an old drill bit on the bottom of the shaft of the bit. Eventually it will come out. You might consider something like WD40 if the bit is really valuable. Make sure you clean the shaft of the bit thoroughly afterward.
When all is said and done, _replace the collet._ There's nothing worse than trying to rely on something that is always getting stuck and it's a real pain to always be trying to unstick bits.
BTW, the two wrench method is far superior to the spindle lock. You might consider removing the spindle lock entirely and just using the two wrenches.