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How to use a Plunge Router

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How to use a Plunge Router

A plunge router is a router in which the motor and collet assembly of the router actually moves up and down along 2 poles attached to the base of the router, meaning that you literally turn on the router, push down and plunge the router into the wood, and engage the depth lock too keep the router down until you're done routing, all the while the base is sitting flush on the piece of wood to ensure control. The depth of the plunge is controlled by gauges on the router, and can be adjusted much quicker then some fixed base routers.

Although much better suited for free hand use then fixed base routers, plunge routers can also lock the base in place to function as a fixed base router, so they are also usable as table mounted routers.

CAUTION:
• Always be sure that the tool is switched off and unplugged before carrying out any work on the tool.

Installing or removing the bit


CAUTION:
• Install the bit securely. Always use only the wrench provided with the tool. A loose or over tightened bit can be dangerous.


• Do not tighten the collet nut without inserting a bit or install small shank bits without using a collet sleeve. Either can lead to breakage of the collet cone. Insert the bit all the way into the collet cone. Press the shaft lock to keep the shaft stationary and use the wrench to tighten the collet nut securely. When using router bits with smaller shank diameter, first insert the appropriate collet sleeve into the collet cone, then install the bit as described above.
To remove the bit, follow the installation procedure in reverse.

OPERATION

CAUTION:
• Before operation, always make sure that the tool body automatically rises to the upper limit and the bit does not protrude from the tool base when the lock lever is loosened.
• Before operation, always make sure that the chip deflector is installed properly.


Set the tool base on the work piece to be cut without the bit making any contact. Then turn the tool on and wait until the bit attains full speed. Lower the tool body and move the tool forward over the work piece surface, keeping the tool base flush and advancing smoothly until the cutting is complete. When doing edge cutting, the work piece surface should be on the left side of the bit in the feed direction.

NOTE:


• Moving the tool forward too fast may cause a poor quality of cut, or damage to the bit or motor. Moving the tool forward too slowly may burn and mar the cut. The proper feed rate will depend on the bit size, the kind of work piece and depth of cut. Before beginning the cut on the actual work piece, it is advisable to make a sample cut on a piece of scrap lumber. This will show exactly how the cut will look as well as enable you to check dimensions.


• When using the straight guide or the trimmer guide, be sure to install it on the right side in the feed direction. This will help to keep it flush with the side of the work piece.

Straight guide (optional accessory)

The straight guide is effectively used for straight cuts when chamfering or grooving. Install the straight guide on the guide holder with the wing bolt. Insert the guide holder into the holes in the tool base and tighten the wing bolt . To adjust the distance between the bit and the straight guide, loosen the wing bolt and turn the fine adjusting screw (1.5 mm or about 1/16" perturn). At the desired distance, tighten the wing bolt (B) to secure the straight guide in place. Wider straight guide of desired dimensions may be made by using the convenient holes in the guide to bolt on extra pieces of wood. When using a large diameter bit, attach pieces of wood to the straight guide which have a thickness of more than 15 mm (5/8") to prevent the bit from striking the straight guide. When cutting, move the tool with the straight guide flush with the side of the work piece.

 

Template guide (optional accessory)

The template guide provides a sleeve through which the bit passes, allowing use of the tool with template patterns. To install the template guide, loosen the screws on the tool base, insert the template guide and then tighten the screws.
Secure the template to the work piece. Place the tool on the template and move the tool with the template guide sliding along the side of the template.

NOTE:
• The work piece will be cut a slightly different size from the template. Allow for the distance (X) between the bit and the outside of the template guide. The distance (X) can be calculated by using the following equation:
Distance (X) = (outside diameter of the template guide - bit diameter) / 2

Trimmer guide (optional accessory)
Trimming, curved cuts in veneers for furniture and the like can be done easily with the trimmer guide. The guide roller rides the curve and assures a fine cut. Install the trimmer guide on the guide holder with the wing bolt . Insert the guide holder into the holes in the tool base and tighten the wing bolt (A). To adjust the distance between the bit and the trimmer guide, loosen the wing bolt and turn the fine adjusting screw (1.5 mm or 1/16" per turn). When adjusting the guide roller up or down, loosen the wing bolt. After adjusting, tighten all the wing bolts securely. When cutting, move the tool with the guide roller riding the side of the work piece.