My DW660 started to sound really bad, like a bearing was going out and the runout became pretty bad as well.
I still like the DW660. For under $60.00 it works really well and mine probably had well over 100 hours of use, most likely more than 200 hours.
Its last job was to cut a set of UHMW mounts for a DW611 1-1/4 HP trim router.
At $120.00 its not cheap and only comes with a 1/4" collet.
Lucky for me Precisebits.com sells precision collets for the DW611.
http://www.precisebits.com/products/equ ... it!!!PG!!!
I went for the 1/8" and 1/4" kit with a balanced collet nut and wrench.
Video of the runout on the DW611 with Precisebits collet and nut.
The DW611 is a beast. Do not try to mount this on a stock shapeoko! It will tear it apart. Dual Y motors and Double X are a minimum and even then the DW611 is probably too much.
It has soft start and an electronic speed control built in. I bypassed all that stuff and modded it to be controlled by a Super PID.

I then used the DW611 to make a dust shoe for it. It blows its exhaust air straight down so I created a diverter/dust shoe to keep the exhaust air separate from the vacuum side. The first iteration was too flimsy and broke in half mid-job so I redesigned it with some 3d pockets to give it a bit more strength. I am also using craft foam for the dust shoe instead of the brush strip. It seems to work pretty well.
I also ordered 1000mm of 4080 extrusion, 250mm of 8020 and a chunk of 5mm carbon fiber plate.
I redesigned all of the motor plates to work with a 80mm tall X axis!
I moved the gantry back on the motor plates a la the eShapeOko and made them 40mm taller.
The Z-axis is now a piece of 8020 with hard coated openrail and steel wheels.
I flipped the Z-axis around so that the extrusion is bolted to a custom plate and created a new spindle mount out of 3/8" aluminum plate.
At the same time my trusty TB6560 controller crapped out on me. The X axis just quit working for no apparent reason (I am sure that my opening it up and soldering a few extra wires in there had nothing to do with it.)

I got it working by using the A-axis for the X and doubling up the Y motors but I had the feeling that was not going to work for very long.
So I ordered a GeckoDrive G540.
I don't have it fully tuned yet, (and one of my Y motors may be going bad) but I now have my maximum rapid rate set to 20000 mm/min for X and Y and my Z is set to 2200 mm/min!
This setup is unbelievable! It is rock solid! It is Sunday and I am not allowed to make noise on Sundays (long story) so I have not had a chance to cut with the complete setup yet but with the new Z-Axis mounted to my old setup I was able to cut out the carbon fiber parts to go to the 80 mm X gantry and it was amazing.
List of new upgrades and mods:
5mm carbon fiber motor mounts.
8040 + hardcoat openrail X-axis
8020 + hardcoat openrail Z-axis
Steel wheels for X and Z
Flipped Z-axis
Dw611
Precision collets for Dw611
New dust shoe/ diverter
Craft foam finger for dust shoe
3/8" aluminum mounts and plate for DW611
Geckodrive G540
48v power supply
Project enclosure for G540 and powersupply
And now what you have all been waiting for.... Pictures!
DW611 dust shoe with two bottom plates.
Carbon fiber pieces cut out.
New Z-Axis