Milwaukee 5616-24 2-1/4 Max-Horsepower EVS Multi-Base Router Kit Includes Plunge Base and BodyGrip Fixed Base

by Milwaukee

Product Description

From the Manufacturer

The Milwaukee 5616-24 plunge base features an exclusive, four-point bushing design and constant spring tension delivers smooth, non-binding plunge action. It has a 6-position (1/8 increment) adjustable metal turret stops. The Milwaukee 5616-24 plunge base also contains durable, nickel-plated plunge rods that resist corrosion and contamination to consistently deliver smooth plunge action. The base has precise macro/micro depth adjustment system to 1/64-inch increments, 3 metal depth scale and adjustable pointer. The Milwaukee 5616-24 plunge base features a depth rod system with quick-release button & locking screw for convenient, precise plunge cut depth adjustment. The patented fixed base body-grip design features precise macro/micro linear depth adjustment system with patented above the table height adjustment. The motor is a powerful 2-1/4-max-horesepower Milwaukee built motor. Kit includes: impact resistant carrying case, dust shield/port assembly durable, dual-position dust shield/collection system for efficient dust management with or without vacuum, 2 clear polycarbonate sub-bases - small hole 1-3/16-inch center & large hole 2-1/2-inch center, concentricity gauge for precise centering of template guides, small hole (1-3/16-inch center) Sub-base and large (2-1/2 center ?) Sub-base assemblies, 2 forged steel collet wrenches, 1/4 & 1/2 premium 8 slot collet and nut assemblies.

Product Description

* Premium plunge system with exclusive four-point PM bushing design & constant spring tension to deliver smooth, non-binding plunge action throughout the entire plunge range (2-7/8 in.) * Patented BodyGrip® design with precise macro/micro linear depth adjustment system & patented above the table height adjustment * Precise macro/micro depth adjustment system to 1/64 in. increment, 3 in. metal depth scale, adjustable pointer, & 6-position (1/8 in. increment) adjustable metal turret stops for precise, multiple-pass routing * Exclusive motor shield design. INCLUDES: * Two 1-1/8 in. Collet Wrenches * 1/2 in. Collet * 1/4 in. Collet * Fixed Based Assembly * Plunge Base Assembly * Two Clear Sub-Bases * Dust Shield * Concentricity Gauge * Carrying Case

Product Details

• Shipping Weight: 26.1 pounds (View shipping rates and policies)
• Shipping: This item is also available for shipping to select countries outside the U.S.
• Shipping Advisory: This item must be shipped separately from other items in your order. Additional shipping charges will not apply.
• ASIN: B000QV1CXW
• Item model number: 5616-24
• Average Customer Review: 4.6 out of 5 stars  See all reviews (41 customer reviews)
• Amazon Best Sellers Rank: #8,934 in Home Improvement (See Top 100 in Home Improvement)
  • #20 in Home Improvement > Power & Hand Tools > Power Tools > Routers

Customer Reviews

Most Helpful Customer Reviews

69 of 70 people found the following review helpful:

5.0 out of 5 stars Milwaukee brings home the Gold on 1st attempt..., November 25, 2007

By 

John W. Thompson "Sarge..." (Atlanta, Ga.) - See all my reviews
(REAL NAME)   

This review is from: Milwaukee 5616-24 2-1/4 Max-Horsepower EVS Multi-Base Router Kit Includes Plunge Base and BodyGrip Fixed Base (Tools & Home Improvement)

I've had problems with my Bosch combo.. (older maganesium base.. switch.. 1/2" collect wouldn't insert.. etc.) and sold it. My DW 621 is a good plunge router after adding a large base, but I occassionally would rotate the plunge release on the left handle and the router would spring up while in the middle of use. Maybe just me but annoying and costly mistakes were sometimes made.

I have had a Milwaukee 5625 under my router table for 5 years and I wouldn't consider anything else but that "hoss". I noticed that Milwaukee had just introduced a plunge router and it came in a kit with that Body Grip fixed base I have used and love.

I took a chance based on my experience with the 3 1/2 HP 5625 and sold the Bosch Combo and the DW 621. Ordered the Milwaukee Combo and it arrived. Started a new bed the following week-end with the Combo getting the call on mortices.. non through dadoes.. intricate joints and with an 1 1/2" over-head bearing template bit used to trim the outline on legs for the foot and head that were 1 1/2" oak after cutting the line just outside 2 mm on my bandsaw.

The results and my opinion based on 35 years of wood butchering are:

Milwaukee nailed the plunge on the first try adding a complimenting plunge to their already proven Body Grip. Motors easy to switch.. bit removal quick and easy.. robust as big brother 5625.. smooth plunge.. power with the 2 1/4 HP.. good dust control attachment.. excellent balance and the best feeling router I have had the pleasure of having in my hands in 35 years.

They took a long time to deliver a plunge to compliment their already robust line... but it was indeed worth the wait at my shop....!

John Thompson... Sarge

77 of 80 people found the following review helpful:

1.0 out of 5 stars Great Except for the Plunge Base, October 17, 2008

By 

Dennis N. Schmidt (Phoenix, AZ United States) - See all my reviews
(REAL NAME)   

Amazon Verified Purchase

This review is from: Milwaukee 5616-24 2-1/4 Max-Horsepower EVS Multi-Base Router Kit Includes Plunge Base and BodyGrip Fixed Base (Tools & Home Improvement)

First off I am not a hater. I've got well over thirty Milwaukee tools and think very highly of all of them with this one exception. For example I feel that the big 3 1/2 HP Milwaukee router (of which I own three) is the best router in the world for router table use. It actually hurts me to badmouth this product since I have such a high regard for Milwaukee tools.

The problem with this plunge base is that the motor is insufficiently clamped into the base as this clamping is entirely achieved by the use of the over center clamp. On a conventional base router this isn't an issue since all of the load on the router bit is tangential. There is no force trying to push the router motor out of the base. A plunge router however is a different animal as when plunging there is considerable vertical force working against this clamp trying to push the motor out of the base. When under high vertical load (like plunging a mortise) the motor backs out of the base. All other multi based routers use this over center clamping system but augment it with a pin on the motor that fits into a slot in the plunge base to prevent the motor from rising up when the unit is plunged. The Milwaukee doesn't have this additional feature.

I solved this problem by drilling and taping a hole into the plunge base for a set screw which I tighten against the router motor to lock it into place. This works fine but something like this should have been done by the factory and not me.

Except for this major flaw the rest of the plunge base is good. The plunge is smooth, the feel and balance of the unit is very good, the depth adjustment system is excellent, and the handles comfortable. I do think that the plunge release lever should be longer as it's a bit hard to actuate, but, the handles intrude into this space making the use of a longer plunge release lever difficult.

Good unit with an unacceptable flaw.

28 of 28 people found the following review helpful:

5.0 out of 5 stars A Terrific Package--on a par with Festool, August 28, 2008

By 

Philip C. Jones (Iowa City, Iowa United States) - See all my reviews
(REAL NAME)   

Amazon Verified Purchase

This review is from: Milwaukee 5616-24 2-1/4 Max-Horsepower EVS Multi-Base Router Kit Includes Plunge Base and BodyGrip Fixed Base (Tools & Home Improvement)

I got this a couple of weeks ago and have since put it through its paces in various hand-held modes. In short, I really, really like this router. In fact, I like it as well as I do a Festool router I bought earlier this year.

Things I like (in no particular order):

(1)The router has clear sub-bases (either acrylic or polycarbonate, I'm not sure which). Furthermore, it comes with two sub-bases, one designed for the Porter-Cable industry standard template guides & one with a larger hole suitable for various larger bearing-guided bits. It also comes with a base-centering guide which is useful for attaching the template-guide sub-base so it is centered. The centering guide seems to work well and easily for me, but this is a purely subjective opinion since I do not have ready access to the type of metrology equipment necessary to determine exactly what lack of centerdness is due to placement of the sub-base, and what is due to a plethora of other possible contributing factors.

(2)It is extremely quiet--about on a par with my Festool (note, I do NOT have equipment to measure decibel output, so this is purely subjective).

(3)The dust-collection attachment works well---actually better than that on my Festool---again, subjective opinion.

(4) The collet nut uses two wrenches instead of a push-in collet lock and single wrench like the Dewalt 625, ELU, and Festool routers. I've got several of the latter, but frankly find the push-in collet lock system clumsy to use and more of a knuckle-buster than using two wrenches.

(5) It is equally adept at both plunge routing and as a fixed base router. This actually came as a pleasant surprise to me since I thought it would inevitably be compromised for either one use or the other. The depth adjustment is smooth operating, exhibited no discernible sign of back-lash, and provides easy to track adjustment in 1/64 inch increments. Again, this is my subjective opinion.

(6) The soft-start and variable speed are nicely done, in my opinion.

(7) Milwaukee kept many of the positive features of their older routers---flat topped base for easy bit changing and superior long split collet (much like what you'd find in the metal working industry).

(8) The router motor is superbly easy to change from one base to another. This, along with the flat top, actually provides another huge convenience. To wit, changing bits on plunge routers has always been an awkward and unpleasant chore, frequently leading to a busted knuckle or two. Now those of you who are less clumsy and more nimble than I may not care about this, but the ability to quickly and easily take the motor of a plunge router out of its base so you can change bits without all of the hassle, why it's just heaven! And of course, since it's so quick and easy to extract from the fixed router base as well, it just makes sense to do that when changing bits as well.

(9) Vibration is remarkably low. Again, I have no way to measure this, so it's just my subjective opinion.

Things I do NOT like:

(1) The case is really, really, really, really horrible. When opened, it falls apart at two seams (hinges?) and is liable to dump the router and other contents on the floor if you're not careful. Furthermore, getting the router along with its two bases properly configured inside the case to fold it back up is something you'll enjoy only if you're an octopus. Thankfully, I don't particularly need or want a case for it, so the case will be going to the re-cycling center ASAP. If a case is important to you, better consider building your own. Did I mention that the case is a nightmare from hell? Thankfully it's not an important component.

(2) The depth adjustment, at 1/64 inch, is not fine enough. Both Festool and Porter Cable do much better than that (1/256th inch for PC and 0.1mm for Festool--which is about the same as the PC). I definitely think this is one area Milwaukee could have done a bit better on. But I knew this going in.

(3) Only collets available are 1/4 and 1/2 inch. I sometimes use 3/8 inch and 8mm shank router bits. Since I don't like using collet adapters (more opportunity for run-out), I'll be forced to use one of my other routers in those cases.

(4) The on-off switch is not conveniently located. Perhaps my hands are just too small, but I have to take one hand off the handle to turn it on or off. I prefer being able to reach up and turn a router on/off while keeping both hands on the handles.


Final comments:

The negatives are pretty insignificant for the most part, and certainly out-weighed by the positives. All-in all, this is a really terrific router package. Since I just love my Festool router and like this one about as much, that's saying something!

I don't know how well the router will hold up over time since I've only had it a couple of weeks. But if it is as sturdy as my other Milwaukee tools have been, I'm sure I'll be pleased. I can tell you that over-all the ergonomics of this router are far better than those of any other Milwaukee tool I've previously owned.

I noted one reviewer who lamented about no router tables being made that will work with this router. I believe just about any major manufacturer of router tables has one that will work. Woodpeckers router plate, for example, (which fits their router table, of course) can be had with a hole configuration that fits the Milwaukee 5619 router. But, since the 5619 and the 5616 use the same sub-bases and hence have the same sub-base hole pattern, you're golden! Basically, you may have to cross-reference and double check a few things, but finding a commercially made table set-up poses no problem. Additionally, many of us have built our own router tables and made our own plates. So go ahead and get yourself a table to fit this router (if that's what you want to do with it) and have fun!