My router just hit the dirt! - Router Forums
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post #1 of 14 (permalink) Old 07-07-2009, 08:14 PM Thread Starter
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Default My router just hit the dirt!

I bought a Woodpeckers plunge lift router lift at the end of May...sort of a early Father's day gift. The lift had been working rather well for me until this evening. I had just released the plunge lock and was raising the router to change bits and the next thing I know I hear this horrible THUD! After inspecting the aftermath, it looks like the only thing holding the router when the plunge lock is disengaged is the red ring (with the index marks) which appears to be press fitted into the rod which comes up through the plate. Over time I can see how this ring could work itself loose. I guess I will be calling Woodpeckers tomorrow...I am in the >30 days but <90 days which means a 15% restocking fee. Has anyone else had this sort of experience with the Plunge Lift?

- Frank
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post #2 of 14 (permalink) Old 07-07-2009, 10:16 PM
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Ouch, hope the motor is OK.

Sawdust is not dirt
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post #3 of 14 (permalink) Old 07-08-2009, 07:46 AM Thread Starter
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Ouch, hope the motor is OK.
I haven't actually turned the router yet, but I am pretty confident it has not been damaged. The arbor turns fine by hand for one and the DW625 is pretty beefy start with. The current table is just an open frame with ZERO dust control so there was a nice padding of sawdust on the floor to absorb the impact

- Frank
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post #4 of 14 (permalink) Old 07-08-2009, 08:27 AM
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I have a WoodPecker Lift, this makes me worry....

Which Lift did you purchase?

And Please let us know what they say.

Thanks
Danny
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post #5 of 14 (permalink) Old 07-08-2009, 09:16 AM Thread Starter
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I have a WoodPecker Lift, this makes me worry....

Which Lift did you purchase?

And Please let us know what they say.

Thanks
Danny
Hi Danny,

It's the Plunge Lift...the low end of the Woodpecker line. I've been studying the lifts on their website. There appear to only be two that support the DW625...the plunge lift and the unilift. The unilift is attached to the plate in six places (4 posts and two screws). The plunge lift is only attached to the plate at the screw (and with the base plate, of course). Therein lies the design deficiency of the plunge lift. You have to disengage the plunge lock to make adjustments and when doing so, all the torque of the adjustment crank is stressing that one connection point. With the weight of the DW625 I guess this just worked loose over time...your mileage may vary.

For those of you who are using the plunge lift, it is imperative that you lock the plunger after making height adjustments! The thought of my router dropping out while the motor is spinning with a cutter runs chills down my back!

- Frank
Woodworking is more than a hobby.
It is a journey of discovery,
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And an opportunity at self improvement.
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post #6 of 14 (permalink) Old 07-08-2009, 09:25 PM
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I would give Woodpecker a chance to make good before I came to any conclusions. They have a good reputation from what I have heard. From personal experience, but not as big a problem as here, they responded very promptly. It would seem that if you router will come off the posts, a safety cable may be in order.
Please post the resolution, if any, from Woodpecker.
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post #7 of 14 (permalink) Old 07-09-2009, 08:11 AM Thread Starter
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Tom, I am going to one better than that...I am going to give this lift another chance. Upon reflection, I am not so certain that the problem may not have been self inflicted...to a degree. Since I now understand the lift design it is clear that the plunge lock mechanism should be engaged at all times except when raising or lowering. Typically I will disengage the lock, raise the router, and then go about making bit changes...with the lock disengaged I think this is where I may be going wrong. All that tugging and torque on the router will put undue stress on that single point of attachment...the lock should be engaged to relieve that stress.

I am also thinking that I may be a bit overzealous when raising the router...it is a DeWalt 625 which can be a bit height challenged, especially under a 3/8" plate. I like to do above table bit changes and try to raise the router as high as possible. Again, understanding the lift design as I do now, it is clear that if you attempt to "over-raise" the lift, you will start to put stress on the lift attachment point and can actually pull it out of the insert plate. This is, in fact, what I think I did the other night. My bad.

I was able to reassemble the lift by using a large dowel with a 5/8" counter bore and a heavy hammer. I have until the end of August before my 90 day return policy expires. I do think Woodpecker makes good stuff, and I'd really like to see if this lift will hold up to the job when properly used.

If there is any value in this thread, perhaps it is to warn other Plunge Lift users of the potential safety hazard operating the router without the plunge locks engaged. The safety cable is also a very good idea and I thank you for that.

More and more I am realizing that the DW625 just isn't the best router in the world for under the table. I know some folks have this all worked out and I don't want to offend anyone, but it seems I keep throwing more and more money at this to make it work. I have been considering buying a second router for portable work anyway, so last night I did something about it...went to Sears and bought the Craftsman 2HP fixed base with intentions of using this puppy as my full time table router. I also ordered the Woodpecker PRL-V2 (how is that for an endorsement of Woodpeckers?). The DW625 is a great plunge router and I will relegate its use to more portable work and some occasional table use when I think I really need the extra HP...maybe even put some skis on it Harry and Bob style.

I appreciate everyone's help and advice, both public and private. This is a great group and I am grateful to be a part of it.

Quote:
Originally Posted by Twill57 View Post
I would give Woodpecker a chance to make good before I came to any conclusions. They have a good reputation from what I have heard. From personal experience, but not as big a problem as here, they responded very promptly. It would seem that if you router will come off the posts, a safety cable may be in order.
Please post the resolution, if any, from Woodpecker.

- Frank
Woodworking is more than a hobby.
It is a journey of discovery,
An application of innovation and creativity,
And an opportunity at self improvement.
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post #8 of 14 (permalink) Old 07-09-2009, 08:38 AM
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Hi Danny,

It's the Plunge Lift...the low end of the Woodpecker line. I've been studying the lifts on their website. There appear to only be two that support the DW625...the plunge lift and the unilift. The unilift is attached to the plate in six places (4 posts and two screws). The plunge lift is only attached to the plate at the screw (and with the base plate, of course). Therein lies the design deficiency of the plunge lift. You have to disengage the plunge lock to make adjustments and when doing so, all the torque of the adjustment crank is stressing that one connection point. With the weight of the DW625 I guess this just worked loose over time...your mileage may vary.

For those of you who are using the plunge lift, it is imperative that you lock the plunger after making height adjustments! The thought of my router dropping out while the motor is spinning with a cutter runs chills down my back!
Mine is the quick lift for the PC router. I looke at the site and see the difference, I dont see this as an issue with the lift I have.

Hope you get the problem resolved.

Thanks
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post #9 of 14 (permalink) Old 07-09-2009, 12:58 PM
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I have a Jessem lift thay I use with my DW625. I always keep the plunge lock on, even when changing bits which I do from above the table. Also my stop nut is still attached, and will not let the router body fall off the guide tubes, leaving the base firmly attached to the Jessem Swiss cheese plate. Sorry to hear about your misadventure and hope all is o.k with your setup.
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post #10 of 14 (permalink) Old 07-09-2009, 01:38 PM Thread Starter
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Originally Posted by jd99 View Post
Mine is the quick lift for the PC router. I looke at the site and see the difference, I dont see this as an issue with the lift I have.

Hope you get the problem resolved.

Thanks
Danny, I agree you are good to go...the quick lift is a much beefier design. I think the Plunge Lift is there as a stop gap solution for larger plunge routers that have too large a form factor to work with the quick lift and precision lift designs. I am going to see if I can make this work and if so, no return, no complaint. Sorry if I alarmed you, but the initial shock of seeing my router drop like that did elicit an emotional response!

- Frank
Woodworking is more than a hobby.
It is a journey of discovery,
An application of innovation and creativity,
And an opportunity at self improvement.
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