Router collet extension

[Bas]

I'm -very slowly- working on some cutting boards. I want to route some handles into the edges using a box core bit. So I created a jig out of some plywood that allows me to use a guide bushing. Complex stuff, this math thing, figuring out how large to make the opening when the outer diameter of the bushing is X and the bit diameter is Y.

All in all that jig took about two weeks

I ran a test piece, and the recess is the right size, but it's not deep enough. Since the jig is made out of 3/4" plywood, I lost 3/4" in plunging depth. Problem. If it was just 1/16" or so, I'd just raise the bit out of the collect, but we're talking 3/8" here...I'm weird, not stupid.

A quick search revealed something called a router collect extender. Bright light streaming down, angels raising trumpets, a choir sings....the Answer! Although for some reason, everyone seems to want to use these things in conjunction with a router table, not a hand held router. So before I spent money on a tool I may only use twice in my lifetime, I want to make sure it's not going to be zero times in my lifetime. (Not that I'd save the money, but it means I can buy different tool! )

- Any concerns using a collet extension in a hand held plunge router (DW61?
- Any concerns using a collect extension in general?
- Anyone have the one from MLCS?

Thanks!

[BKind2Anmls]

I have a 1/2" and a 1/4" collet extension and have used them for years. As a matter of fact, I end up using them more often than not since my router table top is pretty thick. I also use them in a pretty big router, a Bosch 1619EVS and have never had any trouble with their operation. The only issue is finding the correct two wrenches to loosen and tighten the thing.

[Bas]

Just an update - I decided that a router collet extension would be a useful thing to have, since I've had other projects where the extra depth would be really useful. So I ordered the MLCS one.

It comes with two wrenches.

It is nicely machined, all the parts come together nice and tight.

It fits great in the DeWalt 618 router.

It gives you 2 1/4" extra depth.

But, duh, DUH! The extension doesn't fit "through" the guide bushing. When I plunge down, the collet extension hits the underside of the guide bushing when the bit protrudes the outside of the guide bushing by only 1/8". So I've _lost_ routing depth

Double duh.

So I went to Harbor Freight and picked up a new set of guide bushings. As Jim suggested, cut down one using a hacksaw. Sanded it smooth on the disc sander. Made a new template using 1/4" plywood. Works like a charm. Total cost $29.95 for the collet extension (future project?) and $9.90 for the guide bushing set (which includes the 20% off coupon). Plus $16 for the hold down clamps I saw on sale there. And $32 for the multifunction tool. Couple of other loose items...you know how these things go

Other than routing bowls, I can't see too many uses for the collet extension now. Although it would be great for making bench dog holes. Anyone want to buy it? Never used!

[froglips]

Sounds like a win-win! You got to buy more tools and now you have more tools. The best of both worlds

Looking forward to seeing the results.

Jim

[Bas]

Originally Posted by froglips

Looking forward to seeing the results.

I know you meant: No pics, didn't happen

Here is the jig, using 1/4" plywood for the business end (look familiar, Robert? )

View image in gallery

Routed recesses. Almost no burning, very pleased with the $5 Woodcraft bit:

View image in gallery

Yes, I could have used a fence and stopblocks. But routing 4 handles (I made two boards)...jig better. Especially since I'll be making more cutting boards in the future, everyone wants one.

[golfdad]

Agree with Matt...start an stop blocks on router table is what I use

[Canuck]

The routed grab handles look really cool on the end like that, Bas!!

Sounds like you are now well 'tooled' for your next production run.

(Really like that board design, BTW!)

Wayne