Hello, new to the forum(today). Yesterday(Sat Aug 01 2009) I was making arched raised panel doors and smoked my router. It was installed in a bench-dog cast iron table attached to my Unisaw. Never had a problem until now, but it was my first go at arched doors, I was using red oak. Due to the unique table top, I had installed a probably too-smal small cutom box underneath with an attachment for my 4" DC system, and an adjustable air inlet to ensure airflow around the router. Normally, I use a second attachment on the fence, but due to the panel arch, I was free handing the panels with a big scary panel raiser. First use of that as well, I was paying 100% attention to the BSPR, and not much on everything else. The DC never complained or seemed to have changed pitch(the routing made incredible noise, however). I made one pass with all 16 doors using a 1" bearing, and was half way though again with a 5/8" bearing, to finish with the 1/2" eventually. The router abrupty stopped in mid cut. Odd, I thought, and looked at the switch, then breaker panel, eventually opening the access panel in the router box. It was completely packed solid with wood chips. Somehow, the air outlet got blocked(wide open throat at the bit coupled with no fence suction maybe?) apparently directed a whole lot more chips going into the box. Additionally, the cord in the box was partially obstructing the air outlet, and should have been secured better, and the DC was full, probably dropping air pressure. Anyway, I installed my PC690, and finished the doors, but now I have a plunge and fixed base and no Bosch motor. Can these be re-wired? Can I buy just the motor body? I should install a bigger 15 amp router if I'm going to keep doing these types of projects, but they'll burn up just as quick if insulated in wood chips that way. Would be nice to hace a reset switch for overheating. I didn't smell anything until the DC was turned off, then it was awful. If nothing else, this is to inform the community to peridically check things you normally might not be concerned with when performing new or unusual tasks. A larger box to contain the router may have helped, but I should have taken more breaks, and been less complacent about DC. Safety was and is paramount, but I killed a really nice router for no good reason.