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Discussion Starter · #1 ·
Hi, I'm new to the Forum. My current router set-up is a single speed Porter Cable in an INCRA PRL-V2 Lift using my Table Saws Incra 52" Fence. I have only limited experience with Routering. I bought the current setup back in 2009 when we were building the Cottage and we were using reclaimed lumber to finish off the interior. All the Cabinetry, facades and doors had to be made by us to maintain the rustic look we wanted in certain areas

When I retired, we moved into a 100 year old Georgian House. We are slowly working thru the work list in order to get the house back into near original state. The original entry door had been replaced with a new plain looking flat door (84'' x 36" x 1-7/8"), about 10 of the original 8 -12 pane storm windows were replaced with aluminum storms and all the old wooden screen windows are long gone.

Last year I refurbished 32 storm windows; removed all the puttied window panes, stripped them down to bare wood, re-installed and puttied all the panes and then repainted. I added fold-out hardware on some of the storms to allow for easier air ventilation during the summer.

My goal over the next two years is to build a new Entry Door copying the existing interior door pattern, replace the alum. storms with wooden storms resembling the existing storms, build new wooden window screens, and make new "authentic style" trim for the parts of the house where the trim was either damaged or replaced poorly during the past reno's.

I thought the project was going to be relatively straight forward until I started looking at the Rail and Stile & Raised panel bits I thought I wanted and found out from the Freud Tech that my current setup wasn't adequate. I need to upgrade to a Variable Speed Router with more power - my current 1.75 HP - single speed Porter Cable has always been adequate in the past. Not only that my Incra Lift can only accommodate certain routers; I've narrowed my Router options down to the Bosch 1617 (2.25HP) and Milwaukee 5625-20 (3.5HP).

Looking forward, I'll need help in finalizing my new router set-up, how best to match up the bits to the profiles on the existing doors, windows and trim, finding the right bit set that nearly replicates the current construction style (i.e. I want long tenons incorporated at all the major joints) and finding the right bit suppliers with good quality bits (i.e. smooth finish and durable).
 

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Discussion Starter · #13 ·
Thank-you. The articles are perfect for me, great reminders and excellent new learnings.

I decided to go with the Bosch 1617EVS Combo package, the deal gave me a plunger option almost for free, although I'm not sure if I will ever use it. To-date my router table set-up and my dedicated Mortiser have sufficed for my needs. The Bosch is compatible with my current Incra lift set-up which I like very much, and I'm betting the set-up will work for my window needs; which is my main short-term priority. The door project is about a 1.5 years away, and I'm hoping with a bit of practice on the windows that I can make it work on the future door; I might have to use Vertical Raised Panel Cutters. I'll practice with the Cabinet Verticals which I already have; I think my tall fence setup may work well.
 

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Discussion Starter · #15 ·
Thanks for the reply. I had a heritage restoration professional come to the house about a year ago; the city Planning department recommended the guy - the only person in the area doing this type of work. He estimated he needed a full year to do the restorations at $600 Canadian per day; if you do the math it isn't pretty. I had him come in for a day, we worked on a couple of double hungs and I picked his brains. I decided that once I puzzled out how to attack the jobs that I could easily execute my self. Plus I like doing this type of work and learning new skills and its tough watching someone work to standards that don't meet my expectations.
 
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