Customer Reviews

DEWALT DW621 2-Horsepower Plunge Router

5 star:		(10)
4 star:		(12)
3 star:		(5)
2 star:		(4)
1 star:		(3)

 

 

The electronic motor control in this router is a great feature... it ensures constant RPMs at any load. I've never had it overheat. The overall size is much smaller than most other routers. The plunge depth adjustments are extremely accurate... down to 1/128th inch!

And contrary to another reviewer's assertion that a clamp is necessary to keep the switch on, there is actually a trick locking switch. It takes a bit to get used to but is easy after some practice, and it will stay locked under a router table.
Also I've found all the parts to be very sturdy... I don't know how someone could break a handle unless they were trying.

Here are the gripes:

* The router base (fiberglass?) is not well machined... mine was off center a bit so that a corner of the base extended beyond the metal base.

* The base is totally non-standard... you won't find any "universal" kits that fit it, and Dewalt accessories are not found in most local hardware stores.

* To use it in a table you'll need to make a custom base, and find some 4mm (if I remember correctly) metric screws, of just the right length. There are a few randomly placed 6mm utility screw holes on the base, but they are not centered around the router... their mostly on one side, so it wouldn't be a very secure mount. Instead you have to remove the existing base and use tiny 4mm screws. In the end, it's not easy to switch between table mounting and freehand. UPDATE: I purchased a "Veritas" router table... the mounting system uses clamps, so the router's base isn't a problem.

* The spindle lock button is difficult to depress (the spring is too strong) and located in a tough spot. So it's difficult to hold the lock while weilding the wrench to change bits.

* The plunge spring is well balanced against the weight of the router for freehand work, but is tough to fight against when mounted upside down in a router table. A plunge/non-plunge switch would be nice to disengage the spring (or maybe reverse its action?). UPDATE: I removed the spring, so now it's a great upside-down router, but a bad plunge router. (Can't have my cake and eat it too. ;-) It only took a few minutes to figure it out, but a bit messy... not something I'd want to change on a regular basis... easier to just buy another router. WARNING: If you do remove your spring, make sure it is not under tension, to avoid injury; raise the router to it's highest position to take pressure off the spring.

* When I attached a vac to the cool dust collection port it howled like a banshee! The length of the hollow plunge tube is pretty short and sets up for some ear-piercing harmonics when air passes through it. I couldn't find a way to dampen it much... even putting my finger in the intake hole didn't change its tune much. UPDATE: THE WHISTLING SOUND SEEMS TO BE CAUSED BY THE LENGTH OF MY VACUUM HOSE, NOT THE ROUTER ITSELF

* LONG-TERM UPDATE (2011): Being upside-down under the router table means that it eventually clogs up with dust, to the point where it struggles to keep up speed, and gets hot. Cleaning it involves taking a *lot* of parts off... not a job to be taken lightly. Eventually, a brush in the motor broke off (probably because of the heat?) and I was forced to take it apart. After taking it mostly apart, I decided to let a pro finish the job... I brought the the router and all the parts loaded into a 5-lb bucked to my local tool shop. They laughed at the pile of parts in the bucket. But everything was there, and they had no problem finishing the maintenance job I started. That was seventy bucks well spent! And I must say the router hasn't had any other problems in all those years. While my DeWalt was in the shop, I used a rather cheap router in the table for a few things. It was then that I really appreciated the accurate adjustment controls on the DeWalt, and I was happy to get it back.

The end result... great freehand router... unfriendly table router.

The reason I bought this model was for the built-in dust collection through the handle. This one feature alone sets the Dewalt appart from the others. Truly a well designed piece of equipment, and good bang for your buck.

Pros:
Soft start will not jerk the router out of your hands
Smooth Plunging action
Great dust collection, easy clean up.
Well balanced and just the right weight
Has variable speed control
Rack and Pinion depth control is easy/fast to set and use.
Constant speed under load
Plenty of power at 2 H.P.
I like the squared sides on the base. Great when using jigs and fences.
Comes with 1/4" and 1/2" collets
The start switch is located on the handle so you never have to take your hands off the router
Plunge lock is also in the handle... very nice.

Cons:
The two step start switch takes some getting used to.
The router must wind down to a low RPM before re-start. While this can be annoying sometimes, it is bound to increase brush life.
You don't need to buy the fine height adjuster. Save your $$
The edge guide is O.K., not great. But it came as a free accessory.

Overall: I truly enjoy using this router. I recommend this model for hand help operations.

This router has a number of great features that make it a good choice for hand-held operations. The smooth plunge and easily operated downlock, combined with a reliable depth stop, allow repeated plunge cuts with great accuracy. The soft start won't jerk the tool out of your hand.

The included 1/2" and 1/4" collets allow the use of almost any domestic router bits. The through the column dust collection is an innovation, but I have yet to use that feature. The speed control is a roll switch that is easy to use. It has a numbered scale rather than RPMs, which would be more helpful.

I did have some problems when I mounted the router in my table. I purchased a Rousseau base plate, which was difficult to mount due to the narrow rectangular base plate screw pattern on the router. Most after-market base plates mount more easily on round based routers. I also discovered that one of the tapped holes in the router base frame was stripped except for about one turn at the bottom of the hole. The screws are also metric, which are difficult to find out here in the sticks. I ended up drilling and tapping the holes for #10-24 machine screws which I had available.

The factory baseplate would no longer work with the bigger screws, so I made several custom bases out of Lexan, including a round one for use in a dado jig. When mounted in a table, the standard depth adjuster is nearly useless. You will need to get the fine depth adjuster accessory that operates on a screw rather than having to press against a spring.

When using a large diameter bit, I had to remove the plastic dust shroud and it broke as it was removed. I bought a new one but have not installed it, as it is really only needed when using the through the column dust collection.

Despite the problems I had, I would still call this a great tool, but once I have the budget, I will buy a different router just for table mounted operations. This tool really shines in the hand-held mode and it's narrow base will let you get close to posts or other obstructions if you are using it on decks or stairs. It has plenty of power for any bit that can be used freehand.

I've owned this model for about three years and use it under moderate conditions. Soon after my purchase I had to replace two parts that broke on the router. One of the knob handles split and fell off and the metal housing around the collar cracked and came apart. Both were due to cheap components. The broken metal pieces looked like it was made with a cheap metal alloy and the knob was not durable enough to handle the constant twisting motion (on this model the knob opposite the trigger knob is used to lock the plunge in place by twisting the handle). Dewalt replaced the parts for free and without question. I was impressed with their customer service. I have not had any more problems since the replacement of the parts.

There's plenty of power even when using bits up to 2 1/2" milling hardwoods. The soft start and consistant power make it very manageable in hand, but it's not well designed to be used in a router table. The height adjustment is awkward under the table and the on/off trigger has to be depressed by a clamp while in use.

I only gave this router three stars because of the cheap components; but for the money it has been a dependable tool with plenty of power.

I've had this router for about 2 years ( out of waranty )As far as using the router, it's great. This router has never been mounted in a router table, so the bit size has always been under 2 inches. the router recently has started sparking where the brushes are located (replaced brushes , didn't help ). When I took to the dewalt service center they said repairs wouldn't be over a $100 ( a new one with 1 year waranty is only $200. I feel this router should have lasted longer especially since it has had very limited use.

The 621 has been out for a few years now, and it's still the only router w/ a built-in dust control tube and one-wrench collet changing. I also love the way all the controls are in the handles. Maybe these particular designs are patented, but I'm surprised Bosch and PC haven't designed their own similar systems. I always grab this one first for plunge routing unless I need more HP for thick hardwood or a small laminate router. This is as good as they get in the 2HP category. Only caveat: don't try to put it in a table, as it's too awkward to adjust. This is a dedicated plunge router only.

I used this router as my first choice hand held router for several years. I thought that my reason for doing so was simply because it had the best dust collection (it did) but since I ruined it by using it in a table to cut raised panels in mdf which it just wasn't designed to do, I have come to realize that there were other reasons that it had become my favorite.

The fit and finish of all of the height adjustment controls, the easy to use plunge release and the switch built into the handle are all features that none of my other routers have and I just didn't realize it until I no longer had this router and had to go back to some of the others. The ease of changing bits and collets has spoiled me and I despise having to go back to the two wrench method.

It wasn't perfect. The clear cover that is part of the dust collection port was flimsy and one of the little catches broke off about the third time I used it. The removable base was made of some type of fiber-board or fiber glass and was easily nicked or would develop rough edges. The base was oval instead of round, which is my preference and of course there was the problem of the smoking motor (not DW's fault).

I have been looking for a router with the same features that I am missing and at this point it looks like I'll buy another 621.

Pluses - Has a good motor, spins almost like a dentist drill. Good plunge action. I like its size. Good speed control. Good dust collection.


Minus - Base is poorly designed and I can't use a straight edge with it. The casting of the base is rough and not straight and the base plate edge is not a good reference for the center. My Porter Cable 8529 base plate is better referenced. At least it lands on a 32 inch gradient on my strait edge. I will make a base plate to use in conjunction with a bushing so that I can use a staight edge for dados in plywood.

The bushing center is off by about .025" toward the right (fixed handle). It is at least centered between front and back.

I hate the plunge lock mechenism. I want the handle to act like a handle that I can grab without fear of unlocking the plunge lock and having the router pop up. This would be real bad if using a splining bit or a keyhole bit.

I like the position of the PC 8529 dust collector better. The dewault dust port extension gets in the way when inverting the router to change bushings, bits.

I like the PC 8529 height adjustment better. The Dewault has two height adjusters. The micro adjust knob on the Dewalt is for veneer work or tweeking once you've set the main height adjustment and made a test cut. Also, one turn of the micro adjust doesn't correspond to a convenient gradient like 1/8". The PC height adjustment is one continuous thread and each turn is 1/8". Although cumbersome turning the knob, you can get 59/64" without a test cut. The PC height adjust is however, better suited for the router table

I have owned this product for about 2 years, and the total use has been around 4 hours. It has recently failed, so I checked into what it would cost to repair, and found the cost to be around half of the original purchase price. Hardly a bargin. One would think that Dewalt could build a router that would last for more than four hours. Needless to say I will be looking at other manufactures for my next router purchase. I have generally been impressed by the quality of other Dewalt products, but this one appears to be a dud in terms of life expectancy. I own a Dewalt DW708 compound sliding miter saw that has around a hundred hours on it and it has perfromed flawlessly. At least they got that one right.

Purchased the 621 as a result of extensive product test in a publication.

Found the machine to be powerful, easy to use and well designed. Dust extraction is also a very useful feature. Found the base and some parts to be a somewhat crudely manufactured, but overall a workable machine.

I am now in possession of a second 621, the first managed 20 minutes of work before expiring with a load shearing noise and refusing to show any additional signs of 'life'. Fortunately the home improvement store replaced it, no questions.

Experience since then has been very positive. Extensively used with edge guide for heavy mortice work on oak - over many hours with no repeat. Hope this one does not expire shortly after the warranty!