[billyorston]

I replaced a long in the tooth Porter Cable trim router with a Bosch Colt, worked great from the beginning, started to noticed lots of arcing under the lid, then loss of and erratic speed control. Finally it wouldn't even start. Replaced brushes, cleaned commutator, bearings seem tight, very few hours of use. Replaced it with a Dewalt 1 1/4 hp palm router which seems to be fine. Is it worth trying to repair the Bosch Colt? I use the Palm routers for mainly circular cut outs but I am so disappointed with the Bosch.

 

[Nickp]

Sorry to hear...it may have started at the switch since you've replaced the brushes, etc... Was anything wrong with the brushes or commutator when you opened it up...?

Check the operation of the switch with an ohmeter and if you're comfortable troubleshoot the switch under power. Check solder points to make sure they're not loose...

 

[Stick486]

sounds like it isn't clean enough... especially the commutator...
have you called Bosch???

 

[Bstrom]

Which Colt was this? The bottom or top model? That bottom model is not too spiffy looking as it mimics the HF one...I bought the Colt 125 and its a whole different animal. Hope you get this resolved...

 

[Stick486]

see if there is something in these PDF's that will help you..
BTW.. did you seat the brushes and what method(s) did you use to clean the Colt???...
was it dropped???
did you lubricate anything, use any cleaning fluids, strong compressed air, air in a can, vacuum???

.

 

[billyorston]

Commutator very dark, especially in one area, switch looks fine with a meter

 

[Stick486]

check the field and armature...

.

 

[billyorston]

Commutator was dirty, brushes looked fine, very little wear.

 

[billyorston]

@Bstrom The cheaper 1 hp model

 

[billyorston]

@Stick486 Thank you for the detailed PDF advice, much appreciated. After further inspection under a magnifier light I noticed the epoxy had broken down in between a couple of the commutator strips, I tried to re-insulate with some varnish but not successful. A new part is half the price of a new one so heading to the dumpster with it. I bought the Dewalt 1 1/4 hp unit and it seems to work great, very easy to adjust depth. Like I said I use these mostly with a circle cutting jig, maybe I went to deep and overheated the Bosch unit. I typically cut about an 1/8" per pass. I did purchase a new dual base 2 1/4 hp Bosch for doing some slab leveling, hope it holds up!

 

[Stick486]

@Stick486 Thank you for the detailed PDF advice, much appreciated. After further inspection under a magnifier light I noticed the epoxy had broken down in between a couple of the commutator strips, I tried to re-insulate with some varnish but not successful. A new part is half the price of a new one so heading to the dumpster with it. I bought the Dewalt 1 1/4 hp unit and it seems to work great, very easy to adjust depth. Like I said I use these mostly with a circle cutting jig, maybe I went to deep and overheated the Bosch unit. I typically cut about an eighth per pass. I did purchase a new dual base 2 1/4 hp Bosch for doing some slab leveling, hope it holds up!

what species/type of material are you cutting and how much of it, how thick???...
specifically what bit are you using and what is your method???
a dull bit can contribute to a router's over heating immensely...
are you hogging away the waste material before hand???

 

[billyorston]

I have been making lazy Susan's, glue ups from maple, cherry, oak, mahogany, 3/4 thickness. Circle cutting jig, 17 inch diameter, making 4 passes, 1/4" straight bit, usually use each about 3 cutouts and the changing bits, my new 1 1/4 hp doesn't seem to slow down or hesitate or get warm.

Sent from my SM-G955U using Tapatalk

 

[Stick486]

are you using the router for 100% of the cut or close cutting w/ a jig or band saw 1st???...

 

[billyorston]

!00%, I have it up on old 2/4's for support. Two sides of the glue up and nearly zero cut, other two sides are zero to maybe 3"