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Discussion Starter · #1 ·
First post here, and it’s a challenge for the collective wisdom and experience of you fine folks!

I have a Dewalt 625 in a table. I added the Xtreme Xtension by Router Technologies. (Router Raizer still in the box waiting for me to tackle that installation.)

I used it a few times, then my shop time went to zero for nearly a year. Now I can’t get the xtension out of the router. This wouldn’t bother me too much as I intend to keep it in there permanently. This is a dedicated table router, especially once I install the raizer,

But the 1/2 to 1/4 collet reducer is also stuck. I wouldn’t have noticed until I realized that putting a bit in it did not result in any kind of tightening. So it won’t hold a bit, but it won’t come out either. The set screw is out, so that being tight is not the problem.

I have sprayed it with Freeze-off by CRC. I cannot get it to move. (Freeze off is more of a lubricant than actual freezing agent, though it does have a small freezing effect at the outset. It is mostly for cutting through rust. It is what I had on hand.

I am at a loss here. I’m not very mechanically inclined, so I don’t have much experience in getting stuck metals apart without destroying them. I have ordered a replacement collet reducer, they are cheap enough, but I need to get this one out without destroying the xtension. I bought mine in rockler over a year ago for about 75, they are now over 90.

I am thinking of putting the whole thing in the freezer for an hour then trying to remove it. But I wanted to check in with others before I do something like that.

Any advice?
 

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welcome N/A...

for the Xtension; I believe the wedge is jammed into the reducer...


The wedge and bolt work together to secure retain the cutter in the extension.
screw the set screw into the wedge a tad and lightly hit the head of the screw to knock the wedge loose...

as for the router see the PDF....

after you get everything apart clean everything better than really well..
see the maint PDF...

.
 

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Discussion Starter · #3 ·
welcome N/A...

for the Xtension; mechanically spread it open ever so gently..
as for the router see the PDF....

after you get everything apart clean everything better than really well..
see the maint PDF...

.
Thank you for the fast reply.... I confess my ignorance, I have no idea how to go about the bolded part. I don’t even know what tool I should be looking for. I have been trying to hook it from underneath via the recommended paperclip method (From the manualj, and that didn’t budge, so I found something like a dental pick with a handle, and still nothing.
 

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Thank you for the fast reply.... I confess my ignorance, I have no idea how to go about the bolded part. I don’t even know what tool I should be looking for. I have been trying to hook it from underneath via the recommended paperclip method (From the manualj, and that didn’t budge, so I found something like a dental pick with a handle, and still nothing.
see the edited post...
 

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Thank you for the fast reply.... I confess my ignorance, I have no idea how to go about the bolded part. I don’t even know what tool I should be looking for. I have been trying to hook it from underneath via the recommended paperclip method (From the manualj, and that didn’t budge, so I found something like a dental pick with a handle, and still nothing.
you do stand a chance of damaging something w/ that dental pick...
 

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Hi Air Weaver and welcome. Regarding using the extension all the time: imagine that the armature/router extension in your router is a lever. The bottom bearing would be the fulcrum. The longer the distance from the bottom bearing to the force being applied by the router bit the more force being applied to the bottom bearing and also the top bearing. Moral to the story: if you don't really need the extra length then I would recommend not using it. Also members have stated that it vibrated badly when using larger diameter bits.
 

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Discussion Starter · #8 ·
Hi Air Weaver and welcome. Regarding using the extension all the time: imagine that the armature/router extension in your router is a lever. The bottom bearing would be the fulcrum. The longer the distance from the bottom bearing to the force being applied by the router bit the more force being applied to the bottom bearing and also the top bearing. Moral to the story: if you don't really need the extra length then I would recommend not using it. Also members have stated that it vibrated badly when using larger diameter bits.
I installed it so that I could change bits over the top of the table instead of under, and I am starting to see why that “feature” is not a good idea.

I am ready to abandon the whole idea of the extension based on this feedback. But as it is still stuck in my router I am still in a quandary as to how to get it out without damaging the router.
 

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Ah, ok, I re-read it now. Unfortunately the wedge is already out. I removed the screw and wedge easily. But this collet reducer is stuck like Fleck’s tongue on a flagpole in A Christmas Story.
use heat from a hair dryer...
 

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I have a heat gun, so even better!

I was under the impression that heat expands metal though, so I assume this is to apply to the extender, not the collet reducer stuck in the middle?
soldering iron works well too...
more concentrated heat...
 

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@AirWeaver ...
aka N/A...
would you fill out you basic profile...
 

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Is it possible that the router collet is one which still holds the bit tight even though the nut appears to be “loose”. My Dewalt works that way. I loosen the nut initially with a wrench, turn it a few times and it seems to tighten again and the bit can not be removed. A second short turn with the wrench pops it loose and the bit can easily be removed.

The above is my version of the instructions in Stick’s pdf on how a collect works.

Note this applies only to removing the extension from the router not the reducer from the extension.
 

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Heat will often break the bond that is holding them. Penetrating fluid may help too. It's probably a tiny bit of corrosion that holding them together.
 

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Discussion Starter · #16 ·
Is it possible that the router collet is one which still holds the bit tight even though the nut appears to be “loose”. My Dewalt works that way. I loosen the nut initially with a wrench, turn it a few times and it seems to tighten again and the bit can not be removed. A second short turn with the wrench pops it loose and the bit can easily be removed.

The above is my version of the instructions in Stick’s pdf on how a collect works.

Note this applies only to removing the extension from the router not the reducer from the extension.
I did indeed turn further and it loosened, sort of.... now the collet cover (nut?] is sitting as far uo as I think it can go, most threads on the router are now visible. But the extender and nut still will not budge. I keep turning, and it doesn’t seem to go up at all, i can turn it freely with my fingers fir kess than a rotation, then it feels like it engages the threads again, then spins off. So i am rather confident I have it screwed off all the way, still stuck.

I would post pictures but I haven’t gotten to 10 posts yet, so my account is prevented from doing so.
 

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Andy, If the photo is on your computer, you can upload it (no waiting). You must have 10 posts before you can post a link (url) from the internet.
 

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Discussion Starter · #19 ·
Andy, If the photo is on your computer, you can upload it (no waiting). You must have 10 posts before you can post a link (url) from the internet.
Andy, If the photo is on your computer, you can upload it (no waiting). You must have 10 posts before you can post a link (url) from the internet.

Ah, ok, trying it now----- current state of affairs. Heat gun caused damage to the plate from the table. Still no movement of either piece, but I am now mostly just focused on getting the whole extender out. I can deal with the collet sizer on its own after that.

Am I going to have to disassemble the whole router? I am getting the feeling that is the only direction to go. Getting a grip on the extender to pull with any strength is a challenge with the taper. I have a set of pin pullers, but none fit under it really.
 

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Discussion Starter · #20 ·
I would follow The advice from Stick and Chuck to proceed then.
I got a lot of damage to the table insert material with the heat gun so i paused that method. I can unscrew that easily and retry heat, but before I do that I want to figure out how I will even get a hold of the extender to pull it out. I'm really at a loss.
 
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