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soft start/variable speed table setup

32546 Views 175 Replies 27 Participants Last post by  jw2170
greetings all... here is my situation: I've built a custom router table, invested in top of the line accessories blah, blah, blah.. but as of yet, still have not purchased a router. I would idealy want to have remote control (outside of the router box portion of the cabinet) of router motor speed. Right now, the only production router i can find that allows for this is the Milwaukee 5625 sold as a package with remote varialble speed control. This package has reviewed very well and certainly isn't a bad consideration, however, I'd like to know of any other options. From what I've read, the big PC's and Milwaukee's with soft start and VS will not allow for a 'remote' motor speed controller. I've read through the forum and could not find anything that answered my questions, so i figure go straight to the experts..thanks in advance for any assistance...
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what really surprises me about the Milwaukee is just how quiet it is for a big router. I'm sure my cabinet has alot to do with sound deadening, but still...the thing is quieter than my smaller craftsman routers..
Looking forward to watching you get your table started...


helps hoping you and the family have a great holiday!!
It is quiet and it isn't just your cabinet. When I turn it on, my vacuum comes on at the same time. The vacuum is louder than the router when it is not making sawdust. I have yet to have to take two passes at anything. I always wanted a "dedicated" table router and the Milwaukee has been the best solution over any of my other routers. I also bought a Festool 1400EQ for hand held use. It was pricey but after having several PC's and a Craftsman (still works after 35 years but the bearings are getting noisy!!), I decided to step up the food chain this time around.

You have to own or use a Festool to truly appreciate the quality and the engineering that goes into them. I will never buy anything else from now on when it comes to a hand held plunge router.

Unfortunately, I have not had time to play with the Wonder Fence. I have been too busy with the kitchen but it is well made, has lots of features, and should make my woodworking safer when using larger bits. (I will give an update on the WF once I start making the drawers and doors. I will be using cope and stick bits with dovetails on the front drawers. The doors will have raised panels. Between these three techniques, I should have a much better idea if my investment in the WF was worth it.)

Maybe Santa will bring me the Infinity coping sled for Christmas????:jester:

I will keep you posted of any changes. Right now, I just want to finish this kitchen so I can do some things around the house for my wife and self. Now that I have upgraded, my wife has started making a honey do list and I have run out of excuses!!!!

Happy Holidays!
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I have this router too and mine doesn't seem to be much quieter than my other routers..it just sounds different..sort of like a Ferrari alongside a Chevy :D:D:D

I haven't experienced any of the surging issues you described..but I don't have the external speed control kit on mine either so that might have something to do with it?
Greg...

You may have something there.. the comparision is a good one. AS for the surging issues, I'm convinced that it has everything to do with the kit I installed for remote speed control/on/off. I removed the kit on 3 seperate occasions to test the OE setup. and each time I didn't have a problem with the OE parts..

fortunetely in the end, everything has worked out just fine... life is good..
Brad..

FESTOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOLLLLLLLL....

I'm really wanting their orbital sander and vac combo kit!! The RT now collects what I'd say is problably about 95 percent of the dust I create on it. The TS does a good job as well as the rest of the stuff I use. Including the drum sander. But it amazes me how much dust my little dewalt creates and how poorly it collects it. BUT with that said, I don't think the model i have was really made for woodshop type work, considering the lame little dust back it comes with instead of a optional vac. port. I love the chips, the sawdust but that fine stuff can kill ya....
I almost pulled the trigger on their dust collection system but I decided to save my money for the Cyclone system instead.

Cyclone Dust Collection

I really need to get a handle on my dust collection. My masks work overtime!!!

I am not a Ryobi fan but their 8 port sanders have a dust collection port and have lasted longer than my DeWalt orbitals did.

The TS table is also on my list of things to do (storage and dust collection).

Happy Holidays!!!
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The PC soft start and VS are not compatible with remote speed control, but can be used with a remote switch. You can easily wire around and remove the soft start module, then use a remote router speed control. I bought my big PC from a person who said one of the switched were bad. Ended up being the soft start module. It is a common problem. Ten minutes after finding the wiring diagram online it was as good as new, but w/o soft start.
Clouseau...

good stuff, i'm sure there are several in here that would find that information most interesting and usefull..
Last week and a half, I've gotten several emails about the mit-r-slide on the incra fence. I think a few pictures is well worth several thousand words.. give or take a few *S*... Since there remains obvious interest in this project, I hope you folks dont' mind my just posting them for all to see.....

As you'll note, this rig works "WITH" the wonderfence installed. and would not work by itself with just the standard incra fence in place. However, working around that issue I don't think would be much of a problem. Mounting the larger bracket on the right behind with a spacer would probably do the trick. Mounted as shown, the pivot arm extends out over the work surface and would surely get in the way sooner or later. The mount on the left can easily be turned around and used in the same location.

Thus far, it has remained true to the orginal setup. I've not had to adjust anything. I think since the unit is pretty much static at rest or while just using the fence this allows mounting points to stay tight.

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Bill... Thank you.. I hadn't yet figured out how you'd done it. Now I've not got the pictures saved. Did all of that hardware come with the slide? If not, where did you get it? Curious minds, ya know? <g>
The PC soft start and VS are not compatible with remote speed control, but can be used with a remote switch. You can easily wire around and remove the soft start module, then use a remote router speed control. I bought my big PC from a person who said one of the switched were bad. Ended up being the soft start module. It is a common problem. Ten minutes after finding the wiring diagram online it was as good as new, but w/o soft start.
Would you please post the wiring diagram in the "Router Reference" forum? I have one of the big PC's and would love to see it... as will others. :)
Big Jim: Remove the blue wire from the "blue-white-white" bundle. Remove the two black wires from the ss module. Wire nut the two black wires togather.
I'll try to post the print. If not I'll try to find the link. I think I just Googled porter cable 7538 parts. It was at the very bottom of the parts diagram.
Ahh... I found it. I thought you might have the VS model, like I have. I checked out all of the 7518's, but no cigar. I'll check out the 7539 to see if it's there. Otherwise I can take the cap off mine to see if its the same. Thank you!
BigJim...dude,, you need a shave!!! or a body wax!!! *S*

Everything came with the slide, except the 3 short pieces of miter trak I used, 2 for spacer left and right and the 3rd is the cheesy post on the right that i use to rest the miter fence on when not in use..

feeling like an Alaskan spring down here, low teen's/20's, 6"s of snow...dang, an actual winter! First we've had in quite a while...
I didn't know you were looking that closely, Bill.. :lol:

Ahh.. gotcha.. the 2 risers and the stop.. got it!

At 6:30 am this morning it was 32.. reached 35F.. now cooling off, into the upper 20's. Not bad from early January in the "cruel arctic north"! <g>
:sarcastic::lol::sarcastic::nhl_checking::haha:
Questions on parts

Twoskies57, I was wanting to do the same Milwaukee 5625 setup but the form that the original guy did is shut down...probably for money reasons. Do you have the part numbers that you used? I would probably go through my local milwaukee guys for the parts.
Twoskies57, I was wanting to do the same Milwaukee 5625 setup but the form that the original guy did is shut down...probably for money reasons. Do you have the part numbers that you used? I would probably go through my local milwaukee guys for the parts.
Here is a motor only listing for the Milwaukee.

Wish I had done the same. I wound up buying the whole lot.

Milwaukee 5619-29 1 3/4 Max HP D-Handle Router Motor
Twoskies57, I was wanting to do the same Milwaukee 5625 setup but the form that the original guy did is shut down...probably for money reasons. Do you have the part numbers that you used? I would probably go through my local milwaukee guys for the parts.

John...I'm sure I got the parts numbers around somewhere, give me a day or so and I'll get em posted for you..

bill
Thanks Bill, I'm not in a hurry...but I did want to start on the set up for christmas.

John
Thanks Bill, I'm not in a hurry...but I did want to start on the set up for christmas.

John
John,,, here is the original piece that I got the idea from. It is very well written and illustrated.

Milwaukee 5625 Router conversion

If you hadn't read the entire thread, after having upgraded my Milwaukee 5625 I ran into a problem with the router wanting to cut out after only running for a few seconds and then starting back up. Obviously not a good thing!!!! I contacted Day thinking perhaps I had gotten a defective EFM (electronic feedback module). The one thing I noticed was that the time between cutouts slowly began to increase for
whatever reason. After several days of going down and cycling the router on/off/on/off the problem finally disappeared!!! And she's been running just great ever since. The load control feature on the router is fantastic. Its handled everything I've thrown at it with flying colors. I think you'll be most pleased with what you end up with!!

and if you're looking to round out you're rig, Woodpecker/Jessem are closing out production on a couple of very nice Lifts. Several posts already in here regarding the pricing and so on.. Great deals to be had.

hope this helps...

bill
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Thanks Bill, the link worked. I'm not worried about the setup. I studied this thread and decided that what was going on was probably the electric setup ie. the voltage drop on the circuit. High hp motors when they don't get the required power on a line that doesn't support the amperage draw can do some weird things.

Thanks again

John
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