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While I have been a fan of the Bosch 1617EVSPK for some time I've mostly used that router while mounted in my lift in the router table. I recently bough a jig to route the holes for the MFD table type pattern on my workbench using a 1/2" up cut spiral bit. 1st mistake was trying to eke out a bit more depth by extending the depth by moving it further out in the chuck. Don't do this unless you want problems, possibly injury as well. This did ruin the chuck as it spun the bit out of the chuck deforming it. The bit which normally would easily move through the collet now goes less than 1/3 the way in before becoming so stuck it's useless.
So the chuck from the other 1617EVS gets put on and I continue with a new longer bit which now works much better and safer. Lesson learned....And things go so well that I start to skip stopping the router between holes. The jig has 4 rows of 4 holes (16 each setup) which is registered and clamped. The new longer bit just goes inside the 3/4 PC guide bushing when fully up. Then I start to notice that the plunge isn't fully returning as expected and the bit is slightly outside the bushing so I end up buggering a hole which I'll now have to fill with epoxy. OK one more step I didn't want to do. I'm in a hurry as I want to use my bench dogs, fences, and clamps to make and assembly my face frames for the cabinets I'm in the middle of making.
Hint....never be in a hurry, it only leads to more work, possible destruction, and possible injury. Now I'm also a bit tired as the day has been long but I want to finish this part, So on I go and next I eyeball the next row and start my router to make the next series. And this is where it got scary....I should have used the tape measure that was mere inches away but instead pressed forward and began the next hole. Next thing I know the bit is bucking back and forth violently. I quickly discover that while I like the handles on the plunge base I also realize that the power switch is just out of reach. While the router is violently banging back and forth I finally am able to raise and clear the table top. The damage is done to both jig, bit router base, guide bushing and adapter, and table. It happens so fast that there's little time to think, only react.
Pieces of base and bushing adapter fly around the shop. Luckily no one is hurt but words are loudly issued which alerts the better half and that warrants a quick visit to witness the destruction and mess that has now cost a bit of $$. Time to think about what happened and investigate the whole approach and process. Actually that would/should have been the 1st thing done before starting this in the 1st place.
What just happened is the bit just came into contact with a metal brace that holds the top to the adjustable stand ends/ no more than a 1/16" but contact none the less. Might as well been 2" in for all it did. As I peered into the very botched hole I saw the metal edge and where it wildly oscillated I also saw the screw end it also now came into contact with. This threw the router into a violent oscillation that was impossible to control. Enough force was created to shatter the router plastic base, destroy the Porter Cable bushing adapter, and nick the cutting edge of the $67 bit not to mention creating one very nasty hole in the workbench top. Luckily no bodily damage was done. After picking up the scattered pieces, part of the base was 20' away, I tried to fully understand what just happened. I had learned my lesson about stopping the bit before moving to the next hole, had learned to make sure the bit was fully up again, and slow my pace. What damned me on the next move was not making fully sure there were no obstructions (brace/screws) in the way to cause any issues. I also realized that I need a foot switch to use when using this router by hand as there was no way to switch it off as both hands were needed to hold the router.
So now parts are ordered, including the foot switch, and time will be taken to fully understand what had just happened. This isn't intended to be amusing but rather a lesson learned and passed on. These machines are turning these bits at 24,000 RPM. It's faster then you may think generating a lot of force that doesn't stop in an instant.
![Shelf Shelving Furniture Bookcase Plywood]()
Cabinet case, stacked 3 high to save space. One not shown and a corner cabinet as well.
![Wood Plywood Floor Plastic]()
Botched hole.
![Workbench]()
Dogs hole accessories.
So the chuck from the other 1617EVS gets put on and I continue with a new longer bit which now works much better and safer. Lesson learned....And things go so well that I start to skip stopping the router between holes. The jig has 4 rows of 4 holes (16 each setup) which is registered and clamped. The new longer bit just goes inside the 3/4 PC guide bushing when fully up. Then I start to notice that the plunge isn't fully returning as expected and the bit is slightly outside the bushing so I end up buggering a hole which I'll now have to fill with epoxy. OK one more step I didn't want to do. I'm in a hurry as I want to use my bench dogs, fences, and clamps to make and assembly my face frames for the cabinets I'm in the middle of making.
Hint....never be in a hurry, it only leads to more work, possible destruction, and possible injury. Now I'm also a bit tired as the day has been long but I want to finish this part, So on I go and next I eyeball the next row and start my router to make the next series. And this is where it got scary....I should have used the tape measure that was mere inches away but instead pressed forward and began the next hole. Next thing I know the bit is bucking back and forth violently. I quickly discover that while I like the handles on the plunge base I also realize that the power switch is just out of reach. While the router is violently banging back and forth I finally am able to raise and clear the table top. The damage is done to both jig, bit router base, guide bushing and adapter, and table. It happens so fast that there's little time to think, only react.
Pieces of base and bushing adapter fly around the shop. Luckily no one is hurt but words are loudly issued which alerts the better half and that warrants a quick visit to witness the destruction and mess that has now cost a bit of $$. Time to think about what happened and investigate the whole approach and process. Actually that would/should have been the 1st thing done before starting this in the 1st place.
What just happened is the bit just came into contact with a metal brace that holds the top to the adjustable stand ends/ no more than a 1/16" but contact none the less. Might as well been 2" in for all it did. As I peered into the very botched hole I saw the metal edge and where it wildly oscillated I also saw the screw end it also now came into contact with. This threw the router into a violent oscillation that was impossible to control. Enough force was created to shatter the router plastic base, destroy the Porter Cable bushing adapter, and nick the cutting edge of the $67 bit not to mention creating one very nasty hole in the workbench top. Luckily no bodily damage was done. After picking up the scattered pieces, part of the base was 20' away, I tried to fully understand what just happened. I had learned my lesson about stopping the bit before moving to the next hole, had learned to make sure the bit was fully up again, and slow my pace. What damned me on the next move was not making fully sure there were no obstructions (brace/screws) in the way to cause any issues. I also realized that I need a foot switch to use when using this router by hand as there was no way to switch it off as both hands were needed to hold the router.
So now parts are ordered, including the foot switch, and time will be taken to fully understand what had just happened. This isn't intended to be amusing but rather a lesson learned and passed on. These machines are turning these bits at 24,000 RPM. It's faster then you may think generating a lot of force that doesn't stop in an instant.
Cabinet case, stacked 3 high to save space. One not shown and a corner cabinet as well.
Botched hole.
Dogs hole accessories.
