Choosing the perfect router

There are three different sizes of routers: palm, mid-size, and full-size routers.

Palm Router

This is a compact unit equipped with a motor that provides up to 1 HP. It uses a collet that can fit 1/4" bits and is ideal for DIYers new to routing machines. The small size makes them highly maneuverable and suitable for carving decorative inlays and trimming as well as making small dovetail and mortise joints.

Mid-Size Router

This is the most popular size category. Machines in this class have motors with power ratings between 1-3/4 HP and 2-1/4 HP. They use 1/4" and 1/2" collets and are suitable for a wide range of tasks including panel and circle cutting and dovetailing.

Hobbyist woodworkers and professional shops can also use them for template designing. They're available with different bases.

Full-Size Router

This is a production-class tool that is bigger and heavier than mid-sized units. Power output in this class ranges from 3 HP to 3-1/4 HP.

This heavy-duty unit is ideal for large diameter cutters.

The key features to consider are motor power, speed, depth adjustment, and collet size.

Motor Power

While many use horsepower to judge the power of a router motor, amperage is a more accurate measure. Like all cordless power tools, Amperage-hour (Ah) is the metric to use for comparison for battery-powered routing machines. This determines battery capacity and how long the tool will run.

Speed

A routing tool with a higher maximum speed is not necessarily better than one with a lower speed. While faster units produce cleaner cuts and shapes, lower speeds are more effective when carving dense materials.

Variable speed is a more important feature than a very high maximum speed. Soft starting is a good optional feature to have. Tools with this feature start at a slower pace before ramping up to preset speeds. Using a router that starts out at its maximum speed makes for a jarring experience.

Depth Adjustment

The ability to finely adjust cutting depth is essential when performing tasks that are more advanced than edge trimming. Typically, plunge-base models offer finer depth adjustments than fixed-base ones.

Collet Size

Collet size determines the kinds of bits a routing machine can take. A 1/2" collet provides a better grip than the 1/4" collet in smaller tools.

Usually models with 1/2" collets also include adapters for 1/4" collets.

This piece of woodshop equipment makes working with a mid-sized or large routing machine more convenient. Without one, the carpenter has to secure every piece of wood in place before working on it. This is a time-consuming process that using a router table eliminates.

To ease workflow, add features such as a fence to guide cut wood, a dust collector, a slot for a mitre gauge, and a lift for raising and lowering the router.

Manufacturers classify bits by size, material, profile, and design.

Size

Out of the common bit sizes, 1/2" varieties are the biggest, sturdiest, and stiffest. They cut smoother too, since they're less prone to vibration.

Material

Most bits are made of high-speed steel or carbide-tipped. Both materials are very strong and long-lasting.

Profile

There are hundreds of varieties of bit profiles. The most commonly used ones in woodshops are round over, chamfer, cove, V-groove, dado, dovetail, and rabbeting.

Design

A bit can either be edge or non-edge. An edge unit has a replaceable wheel bearing that acts as a fence. This is especially useful when carving edge mouldings. Non-edge ones require external fences attached to the workpiece or built into the router table.

An anti-kickback bit has a limiting extension around its shoulder to prevent the wood from pushing too deeply into the cutting edge of the bit.