Hi All, just wanted to report back on my Dewalt Trim router experiment.
Tonight, In between tasks, I managed to squeeze in the new UHMW mounts to accomodate my Dewalt Trim Router. I bought it from amazon about a month ago for about $55. Delivered. (Here's the link
I used the same material to make the mount (3/8" white UHMW) and mounted it the same way as the dremel (bolts into insertion nuts, slid into the z-axis extrusion). There is an issue with my design that didn't accomodate an M5 x 10mm bolt and was too long for a M5 x 16mm bolt, so I had to use washers between the mount and the extrusion to make it work. Not the best scenario, but it seemed to work. I'll try to get the revision done to the parts and post the mount for anyone who is interested in giving it a try.
A couple of random notes:
- It's bad ass! (for lack of a better phrase) Plain and simple. Going from a 1A rotary tool to a 5A is like night and day.
- I was using a 1/8" 2 flute endmill (HSS) taking 1/8" depth passes at 80ipm. I never heard boo from the trim router. At those speeds and depth, my rotary tool would have stalled. I think I could have gone faster. The next time I have a while to just play, I'll crank up the speed and see where the limit is.
- The DW660 came with both 1/8" and 1/4" collets. I have only used the 1/8" so far.
- It's a little nosier than the 1A rotary tool. Really, just a little bit. I'll try to get a readout with my android app to compare. But it's not as high pitched, if that makes any sense?
- Plunging was awesome. Plunging straight down is the worst thing you can do with an endmill. Even a center point endmill. There's a point when the bit bites into the material where there's simply no room for the chips to go, and as such it's tough on the tool and the spindle. Again, the DW660 didn't flinch at plunges.
- Cutting UHMW at higher speeds with deeper passes is better! For one, it's a lot faster. But, regarding 'machining' it appears that the material wants to be done at a higher speed. The chips that came off were slightly bigger, and I didn't see any stringing or melting.
- Weight - slightly more than the rotary tool, but not by much. I should put them on my food scale to compare. (my wife will love that...)
- Size - the DW660 is about 1/2" larger in diameter than the Rotary tool (at their largest points). Regarding workable room, I don't think the extra size shrunk the work envelope by any more than 1/2" in the Y axis.
- Runout - no way of telling really.
I took a picture of the setup on my phone, but using it as a wireless hotspot killed the battery, so we'll have to wait until it charges before I can upload the picture.
All in all, really good stuff. And for $55... I should have made the switch a long time ago.