Dw621 Router Manual: Discover the Benefits and Capabilities of Your DeWalt Router

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Mid-size routers provide more power, use bigger bits, and accept a wider array of bits and accessories to manage larger workpieces, cut harder woods, and produce higher volumes of work than compact routers. They perform large-scale edge forming, slotting, grooving, tracing, dovetailing, panel trimming, and circle cutting tasks.

Dw621 Router Manual

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Lock-On/Lock-Off Switch (Fig. 7) The lock-on/lock-off switch is located in the handle on the right side. The router is normally locked-off. To start the router, press the thumb lock and squeeze the trigger. To lock the switch on, squeeze the trigger, press the thumb lock forward and release the trigger. To turn the router off, release the switch. If the tool is locked-on, press the trigger again and release the switch.

Pat's a trusting soul ... after reading about his offset subbase for the DeWalt 621 router I decided to get one. I emailed him, asking if the price of $46 included shipping and tax, as I was planning to buy one. He sent it to me prior to payment, and I guess that's the way he works. I fear his trusting nature has been violated before and will again, but I made sure I got a check out for the sub base in today's mail.

I'm not a big fan of buying things I can make ... that's what a shop is for, after all. But the DeWalt 621 is a unique critter ... the cutter hole is offset in a rectangular base. So having a base pre-made makes sense ... it might take me a while to get the base and cutter configured correctly doing it myself. The pics below show his site's pictures of the base and the router.

I emailed Pat Warner and let him know the check was in the mail, and that I'd let him know how I like the base once I get the holes tapped. He was very surprised that the holes weren't tapped already ... and wanted to get the serial number and country of manufacture of the router. So I sent him that and a few pictures so he could see the holes were simply pilot holes.

It was easy enough to tap the threads with a new 6mm tap I bought from the local "Do It Center", and the base fits perfectly. I'm in the middle of the boat-cradle project, so I haven't used the router yet.

I got some reassurance from the DeWalt web site today ... the manual I have is the current one, and they have an exploded diagram so I can compare what I got to what I was supposed to get! I still don't know the year of manufacture, but I'm no longer worried about the only date I can find on the instruction manual ... 1996 (the copyright date). The router seems well made, so I think the only problem was the holes were not tapped in the base. The router says it was produced in England.

First, what kind of router you got? If my memory serves me correct, that looks like the base of a Bosch 1617 EVS. If so, I wondered the same thing when I mounted. You can call Bosch tech support (number in your owners manual) to clarify. If some other router, I can clarify what I did. The Bosch tech told me the unthreaded holes were 1/4" which they're not.

I plan to call Dewalt, but would not be surprised if they, mindful of product liability lawsuits, just said "We do not recommend using a handheld router in a table" and refuse to tell me how to attach it.

Although I am inordinately pleased to have even a primitive router table, I am already wondering how to improve it. Inserts, for example. Is the cutting portion of the bit always above the table, so only two inserts are needed (to accommodate 1/4" and 1/2" shanks)?

Remove the subplate from the router, place it bottom-side-up on the top side of the plywood, with the opening over the center mark. Mark the holes for the mounting screws (see plate.jpg). Drill and countersink the holes.

6mm is not a lot of screw to hold the router in only two positions. I'm not saying it wouldn't, but watch carefully for any movement or tilt of the bit to the side once mounted. Please check this as IMO, I don't consider it adequate. The weight of the router and the over 20,000 rpm meeting hard-wood can cause the screws to loosen and back out. 6 mm is not a big screw.

My opinion ( and I am no engineer ) I would use the two additional holes in the base and drill and counter-sink two additonal in your table or insert and add two more 10mm screws. Attach with a nut and lock washer on top of the router as they will be hidden under-neath the table or insert anyway. Could even use thumbscrews for quicker release if you use the router both ways. Now you got heavy-duty and a safer scenario.

I make most of my tables and cabinets. The picture is a combo router and edge-jointer I made with 2 sheets MDF glued and screwed. Both sides sealed with laminate. I designed the fence which has a sliding 2 portion face. I can add shims behind the outfeed portion and with a straight bit perform edging. The home-made cabinet has storage in the bottom and the shelf catchs sawdust in the top. The cabinet also reduces noise. With a built-on dust port in the fence I get literally no sawdust escape.

Elu made CNC router tables also. For bit changing the router was changed and the holes were for dowel pins for lining up the router. Since DeWalt is not selling that side of Elu, it's not surprising that they wouldn't know what those pins were for. There are some web sites that discuss the cnc machines.

....Did a little more searching and it seems some router inserts also use pins for multiple table operations. The pins are used to ensure consistent router to fence distances. The article I read had to do with making raised panels with multiple tables. Guess the tapered head screws are not considered to be accurate enough for such operations.

I was interested in the Elu as from what is said here, the DW is their design. I am sometimes leary of DW. They got their hits and misses as all tool companies. The DW scroll was designed by Excalibur and is good. If that plunge router was designed by Elu, it is worth looking into. I have a Bosch EVS mounted in the cabinet and a PC plunge that was part of a combo kit. The PC from the kit is not everything I want it to be. They have a great plunge, but I won't pay the price. Just looking at the DW as an option as I can usually get a reco from a service center about 12 miles away. 2ff7e9595c