Router

Description

A Router is a hand tool or power tool that routs (hollows out) an area or “pocket” in hard material, such as wood or plastic. A Router can also be used to create chamfered, coved, beveled, rounded or otherwise, decorative edges on a piece of material.  Routers are mainly used in woodworking, especially cabinetry. Usually they're handheld or fastened, with the cutting end up, in router tables.

A router employs a spindle driven by an electric motor, and various cutting bits can be installed in the collet at the end of the spindle. We have four different types of routers in the SOA: A fixed base router, a plunge base version, a smaller lighter version designed specifically for trimming laminates, and a table-mounted version.

Routing is a high-speed process of cutting, trimming, and shaping wood, metal, plastic, and a variety of other materials.

• The set-up includes an electric driven router, a cutting tool, often referred to as a router bit, and occasionally, a guide template. Also the router can be fixed to a table or connected to radial arms, which can be controlled more easily.
• In general there are three types of cutting bits or tools (Router bit types).

1. Fluted cutters (used for edging and trimming)
2. Profile cutters (used for shaping and trimming)
3. Helical cutters (used on easily machined materials, for drilling, shaping, trimming)

The router is positioned at the finer end of the scale of work done by a moulding / profile cutter. That is to say it is able to cut grooves, edge moulding, and chamfer or radius the edge of a piece of wood. It is also possible to use it for cutting some woodworking joints. The shape of cut that is created is determined by the size and shape of the bit (cutter) held in the collet, and the depth, by the depth adjustment of the sole plate. In the SOA, we typically use a ¼” Collet and a ½” Collet with attached nuts, since all of our router bits have either a ¼” or ½” shank diameter.

Features

The tool usually consists of a base housing a vertically mounted universal electric motor with a collet on the end of its shaft. The bit is height-adjustable to allow protrusion through an opening in a flat sole plate, usually via adjusting the motor-mounting height (the mechanism of adjustment is widely varied among manufacturers). Control of the router is derived from a handle or knob on each side of the device, or by the more recently developed "D-handle".

There are two standard types of router—plunge and fixed. When using a plunge-base router, the sole of the base is placed on the face of the work with the cutting bit raised above the work, then the motor is turned on and the cutter is lowered into the work. With a fixed-base router, the cut depth is set before the tool is turned on. The sole plate is then either rested flat on the workpiece overhanging the edge so that the cutting bit is not contacting the work (and then entering the work from the side once the motor is turned on), or the sole plate is placed at an angle with the bit above the work and the bit is "rocked" over into the work once the motor is turned on. In each case, the bit cuts its way in, but the plunge router does it in a more refined way, although the bit used must be shaped so that it bores into the wood when lowered. Plunge-cutting Router Bit

The baseplate (sole plate) is generally circular (though this, too, varies by individual models) and may be used in conjunction with a fence attached to the base, which then braces the router against the edge of the work, or via a straight-edge clamped across the work to obtain a straight cut. Other means of guiding the machine include the template guide bushing secured in the base around the router cutter, or router cutters with built-in guide bearings. Both of these run against a straight edge or shaped template. Without any type of guide, the varying reaction of the wood against the torque of the tool makes it impossible to control by hand, with the precision normally required.

Personal safety

1. Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.
2. Use safety equipment. Always wear eye protection. Safety equipment such as dust mask, non-skid safety shoes, or hearing protection used for appropriate conditions will reduce personal injuries.
3. Avoid accidental starting. Be sure the switch is in the off-position before plugging in. Carrying power tools with your finger on the switch or plugging in power tools that have the switch on invites accidents.
4. Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury.
5. Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
6. Dress properly. Do not wear loose clothing or jewelry. Keep your hair and clothing away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.

Power tool use and care

1. Do not force the power tool. Use the correct router bit (cutter) for your application. The correct router bit will do the job better and safer at the rate for which it was designed.
2. Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.
3. Disconnect the plug from the power source before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.

Additional Specific Safety Rules

• Hold tool by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or its own cord. Contact with a “live” wire will make exposed metal parts of the tool “live” and shock the operator.
• Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against your body leaves it unstable and may lead to loss of control.
• Never run the motor unit when it is not inserted in one of the router bases. The motor is not designed to be handheld.
• Keep hands away from cutting area. Never reach under the workpiece for any reason. Keep the router base firmly in contact with the workpiece when cutting. Hold the router only by the handles. These precautions will reduce the risk personal injury.
• Use sharp cutters. Dull cutters may cause the router to swerve or stall under pressure.
• Never touch the bit immediately after use. It may be extremely hot.
• Be sure that the motor has stopped completely before you lay the router down. If the cutter head is still spinning when the tool is laid down, it could cause injury or damage.
• Be sure that the router bit is clear of the workpiece before starting the motor. If the bit is in contact with the workpiece when the motor starts it could make the router jump, causing damage or injury.
• Do not press spindle lock button on the Laminate Trimmer Router while the motor is running. Doing so can damage the spindle lock.

Set-up / Operation

To reduce the risk of injury, turn unit off and disconnect it from power source before installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.

Installing the bit

To remove the motor unit from the base unit:

1. Open the clamp (A) Fig. 1.
   1. While holding the base, turn the power unit COUNTER-CLOCKWISE until the lower pin (B) Fig. 1 in the motor housing is disengaged from groove in base.
   2. Lift the power unit free from the base unit.
2. Clean and insert the shank of the bit into the collet until the shank bottoms-out then back it out approximately 1/16".
3. Lay the power unit on its side on a bench with the collet pointing AWAY from you.
4. Place one wrench on the flats of the chuck with the opposite end of the wrench resting on the bench to your left (Fig. 2).
5. Place the other wrench on the collet and tighten COUNTER-CLOCKWISE. Tighten firmly.
6. To remove the bit, reverse the procedure.

To avoid possible damage to the collet, never tighten the collet without a bit.

Installing the motor to the base

To reduce the risk of injury, turn unit off and disconnect it from power source before installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.

1. Open the clamp (A) Fig. 1 and set the power unit in the base unit.
2. Align the lower pin of the power unit (B) Fig. 1 with the groove in the base.
3. Rotate the motor CLOCKWISE into the base until the upper guide pins are set in the groove of the base.
4. Close the clamp.

Adjusting the Depth of Cut (Fixed –Base Router)

The following directions refer to Fig. 3.

1. Open the clamp (A).
2. Hold the base (E) and turn the power unit (F) counter-clockwise until the tip of the bit is above the bottom of the base.
3. Set the tool on a flat surface.
4. Turn the power unit (F) clockwise until the bit touches the work.
5. Close the clamp (A).
6. Rotate the depth-adjusting ring (B) until the zero-line (C) is opposite the index line (D) on the housing.
7. Open the clamp (A).
8. Tip the router so that the bit is clear of the work surface. Turn the power unit (F) Fig. 3 clockwise until the index line (D) on the motor housing reaches the desired depth indicated on the ring.
9. Close the clamp (A).

NOTE: Setting the index line to 1/4" on the ring means the cutting edge of the bit is exposed 1/4" below the base.

Connecting to Power Source

Before connecting tool to power source, check to see that the switch is in the "OFF" position.

Starting and Stopping the Motor

Before starting the tool, clear the work area of all foreign objects. Also keep firm grip on tool to resist starting torque.

To start the tool, move the rocker switch (B) Fig. 18 to the "ON" or "1" position. To stop the tool, move the rocker switch to the "OFF" or "O" position.

To avoid personal injury and/or damage to finished work, always allow the power unit to come to a COMPLETE STOP before putting the tool down.

Using the Tool

Always be sure the work is rigidly clamped or otherwise secured before making a cut. When routing the edges, hold the router firmly down and against the work with both guiding knobs. Since the cutter rotates clockwise (when viewing router from top), the router should be moved from left to right as you stand facing the work. When working on the inside of a template, move the router in a clockwise direction. When working on the outside of a template, move the router in a counter- clockwise direction. Avoid “Climb-Cutting” (cutting in direction opposite that shown in Fig. 20). “Climb-Cutting” increases the chance for loss of control resulting in possible injury. When “Climb-Cutting” is required (backing around a corner), exercise extreme caution to maintain control of router. The speed and depth of cut will depend largely on the workpiece. Keep the cutting pressure constant but do not crowd the router so the motor speed slows excessively.

On exceptionally hard woods or problem materials, more than one pass at various settings may be necessary to get the desired depth of cut.

When making cuts on all four edges of the workpiece, make the first cut on the end of the piece across the grain. If chipping of wood occurs at the end of a cut, it will be removed when making the next cut parallel with the grain.

Clean-up

When you are finished working with a router at the workbench, or router table, clean the area before leaving the workstation. There are 4 Blue Trash barrels (image needed) in this room, and each one has a broom, bench brush and dust pan attached. You must use these items to clean up your work areas at each machine, or table, when you are finished working there. Also, there are scrap barrels at each workstation to deposit scraps of material, which may be useful for someone else. Please do not put materials with stray hardware or glue on them, or food/drink items, only re-usable materials should be put into the scrap barrels. Anything else should be put into the Blue trash barrels.