Expert: Jamie Yocono - 12/15/2010

Question
Hi Jamie,

I have a DeWALT DW621 plunge router and a Wolfcraft 540 router table.  This is the first time I am trying to use the router with the table.  I attached the router to the square plate that comes with the table, and then attached the router/plate to the bottom of the table.  When I adjust the router upward, to raise the bit through the hole in the table, the router stops going upward before the bit is far enough out of the table.  The bit I am using is to cut a groove in 3/4" maple flooring.

The router is moved as far as it will go, and the thickness of the table prevents the bit from protruding enough.  What is the solution here?  Thank you,

Bill

Answer
Bill,

I'm not familiar with that exact model of DeWalt router, but I've had the same situation occur with other routers. In both cases, there are only two solutions - either eliminate some of the thickness of the router table top, or buy a longer bit.

For example, I use the Porter Cable system. I've mounted those both in Porter Cable router tables, and on the underside of my tablesaw table, sharing the fence with my tablesaw. Since the tablesaw table is 3/4" melamine, there have been times when my bits simply aren't long enough to protrude high enough to cut the profile I want. In most cases, I can either switch to a longer bit (if it's a straight cutting bit, with no bearing, or switch to the router table, which has a very thing tabletop.

It's somewhat the nature of the beast, sorry to say. You'll see lots of aftermarket drop in tables, to eliminate that exact problem. Some of the best solutions I've seen are simple 1/4" plexiglass inserts. You can cut that material to the size you need, and it's thin enough to not take up too much depth.

Sorry there isn't really a better answer. Remember that line in Jaws, when the fisherman finally saw the size of the shark and simply said - we gotta get a bigger boat? In this case, you gotta get a bigger (longer) bit. :/

Jamie in Vegas

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Jamie Yocono
Wood It Is! Custom Cabinetry
Las Vegas, NV
www.wooditis.com
My woodworking blog: www.wooditis.blogspot.com