[Poloris]

I wanted to use my Dewalt 610 to cut dovetails on a leigh dovetail jig.
However I found I could not reach the toggle switch whilst my hand was on the handle, also the the knob like handles were slippery so I could not wrap my hand around them.
These things made the router not so suitable for the task.
I explored the idea of using a footswitch but that did not work out for me.
So I re-examained my issues with the dewalt and decided to fit taller and more grippy handles.
The stalks were machined out of aluminum, the handles are rubber bicycle handle bar grips and are filled with 7/8 nylon solid rod.
I machined the slots in the handles through the grips.
I have included some photos of the manufacturing for those who may wish to do something similar.
To get the angles right I fitted the stalks upside down used the complicated clamping arrangement shown in one of the photos, to mill flats for parallels on one side of the stalks.
If I was to do it again I would reduce the rake of the handles a little.
But I am more than pleased with the results.
Mark

 

[Cherryville Chuck]

That's pretty nifty Mark. Why didn't the foot switch work for you? I have a 610 and I've used my foot switch with it.

 

[fire65]

Good job man, those should give you lots of control.

 

[Poloris]

Chuck the problem is I could not buy a suitable latching footswitch in Australia.
Its a small market.
Importers won't pay the expense of applying to the the regulator to have a product certified for mains power (250 volt 50 hz) unless the return is substantial
Mark.

 

[Nickp]

I wanted to use my Dewalt 610 to cut dovetails on a leigh dovetail jig.
However I found I could not reach the toggle switch whilst my hand was on the handle, also the the knob like handles were slippery so I could not wrap my hand around them.
These things made the router not so suitable for the task.
I explored the idea of using a footswitch but that did not work out for me.
So I re-examained my issues with the dewalt and decided to fit taller and more grippy handles.
The stalks were machined out of aluminum, the handles are rubber bicycle handle bar grips and are filled with 7/8 nylon solid rod.
I machined the slots in the handles through the grips.
I have included some photos of the manufacturing for those who may wish to do something similar.
To get the angles right I fitted the stalks upside down used the complicated clamping arrangement shown in one of the photos, to mill flats for parallels on one side of the stalks.
If I was to do it again I would reduce the rake of the handles a little.
But I am more than pleased with the results.
Mark

Kudos on the modification...just keep in mind one of the benefits of down-low handles on the base is safe control while routing...be careful of tipping when pushing high...

 

[AndyL]

That's a great modification Mark, nice work.