Customer Reviews

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

5 star:		(31)
4 star:		(7)
3 star:		(0)
2 star:		(1)
1 star:		(2)

 

 

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

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.

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!

I got the router for my birthday based on the review in June 07 Popular Woodworking. The machine is fantastic. The body makes the router feel much smaller and handle much easier than its 2-1/4HP would suggest. You can easily work single handed if you want with smaller bits. The rubber body and grips offer a positive feel and are very comfortable. The plunge action is smooth and the plunge lever is right at your fingertips. The switch can be reached with both hands on the router, although with the soft start it's not necessary. The case will keep everything clean when not in use and offers lots of storage for 1/4" and 1/2" bits along and a set of template guides.

Highly recommended.

After purchasing a Milwaukee Sawzall from Amazon and being very pleased with it, I was in the market for a router and was impressed with the Milwaukee height-adjustment design. My first purchase was a reconditioned 5615-81 1-3/4HP router. Although it was supposedly tested and inspected at the factory, there was a 3/4-inch long piece of metal rattling around inside the motor housing. It looks like part of a motor armature. Luckily, I discovered it before I plugged it in. It was fairly easy to remove, but Milwaukee quality control should have caught this.
Next, I decided to purchase this 5616-24 kit from Amazon. No rattle, but upon plugging it in and turning it on, there was a noticeable recurring vibration in the motor that increased with the speed adjustment. At the slowest speed, it pulsed about every half second and was strong enough that it would have disturbed cutting. The motor was also much louder than that of the 5615. I contacted Milwaukee Tech Support and they simply said that this was a variable speed unit with soft start, and deferred me to the local service center. Terrible.
Fortunately, Amazon customer service took the old one back and sent a replacement. The new kit arrived today and is smooth and buzz-free. Again, Milwaukee quality control should've caught the problem before shipping it out.
As for the rest of the kit, this and the 1-3/4HP kit are the best deal if you need both the plunge and BodyGrip bases and the clear sub-bases. The height-adjustment wrench and dust collector are of limited use to me. I still need to reach under the table to loosen the clamp before adjusting the height. The dust collector looks and feels really cheap. It is held in place by a U-shaped piece of metal which clamps to the edge guide holes. When using the edge guide, the U-shaped piece is removed and the collector is held in place by the edge guide rods. Speaking of edge guide, they should've included one, although the Milwaukee guide looks cheaply made. The gargantuan case will probably go into storage. The smaller case that came with my reconditioned router is much more handy.
The 1-3/4 and 2-1/4HP motors, bases, and accessories can be used interchangeably. If you look at the parts diagrams on the Milwaukee Web site, you'll see that the added height of the red cap is to accomodate the electronic module. The motor housings are the same, just a different armature and field. The soft start feature is more like a delayed start. After flipping the switch, just as you start thinking that the unit is defective, the motor comes on. There is still quite a bit of starting torque transferred through the grips.
The plunge base is excellent. Plunge is smooth and controls are well placed, and it comes with the 1-3/16 clear sub-base installed. My only gripe is the cheesy stop rod and stop screw. It looks like it was made in the same factory as the other router accessories.

Milwaukee 5616-24....Quiet, smooth, user friendly.....What can I say, except, it's better than I expected. GREAT !!!! Put the fixed base under the router table, and use the plunge base for free hand work....Haven't used it much yet, but it slips in and out of the bases so quick & easy, (Quicker than finding, and inserting wrench), I haven't worried about the above the table height adjustment yet. Will have to drill a hole to accomodate wrench if I decide to use it. The micro adjust knob makes height adjustments in a snap too...

I purchased the Milwaukee 5616-24 to supplement my Bosch plunge router. I often cut tenons of various sizes and having two plunge routers set to different depths allows me to finish the parts faster. I specifically wanted a new router that had a better method of selecting the plunge depth. Although my Bosch's manual claims adjusting the depth is easy, adjusting to a specific depth within a .010 inch tolerance requires too many test cuts. The reason being the microadjustment knob moves both the bit and the depth control rod. Making fine adjustments requires several steps, not just moving the microadjustment knob. The depth adjustment mechanism on the Milwaukee 5616-24 only moves the depth control rod. This simplifies the process and allows quick depth changes. Another feature I like about the Milwaukee is it has two springs to suppport the plunge base. The single spring in the Bosch plunge router often allowed the unit to bind when plunging. This would prevent the bit from making a smooth controlled entry into the work piece. The Milwaukee's plunge base is much easier to control.
I also have used the fixed base. It was very easy to remove the motor from the plange base and install it in the fixed base. Regardless of the base the router performed well. I like the soft start and the motor seems to have plenty of power. I have not used it mounted in a table so I can not comment on those features. The only Bosch feature I think I prefer is the shape of the base. It has a D shape rather than being completely circular. Since I prefer to use a fence instead of a guide attachment, the flat part of the base allows you to keep the router in the same position (i.e. It does not rotate.) through the entire cutting motion. This is not a large advantage, because the base centering cone that comes with the Milwaukee does an excellent job. Although the router rotated slightly while I moved it along a fence, there was no noticeable undulation in the resulting edge.
To date I have only used it to build one table, but I am very pleased with its performance.

I purchased this router combo in april to supplement my milwaukee table mounted router. First, the durable plastic case is large and everything fits inside nicely. The compact fixed base is comfortable and will be familiar to those who have used other milwaukee body grip routers. The plunge base feels robust but the plunge lever is very stiff. I thought that it may loosen after some usage, and it did improve gradually, but it made routing deep mortises a chore. Make no mistake, it works, it is just very stiff. Another issue involved the two milwaukee supplied 1 1/8 wrenches. One of the wrenches was forged incorrectly and would not fit on the collet. After a phone call to Milwaukee, a new wrench arrived a few days later. I gave this router 4 stars because it is powerful, has a excellent fixed base, decent plunge base, and a solid 5 year warranty.

When my 10 year old pc 690 starting spitting our its bush caps mid run, I new it was time for a new router under the table. Having owned a pc 7529 I know what smooth, quiet, and powerful feels like. The only problem is the micro adjust on the their plunge is idiotic "plunge the router,hold it down and turn the knob until it touches the surface, then turn the knob the other direction until you feel resistance, up to 20 turns!) And this you do every time you want to use it, give me a break! The 890 series has horrible reviews (one half a turn backlash in the adjustment knob and slop in the alignment) What does one do?

I almost bought the triton for its above-the-table bit change but read of their nylon parts in the rack and pinion failing and I really didn't want another loud router or their stamped sheet metal accessories.

I have owned a milwaukee hammer drill for 10 years, it still wacks out tapcon holes like a banshee. MADE IN GERMANY.

The Popular Woodworking review sold me on this router. The standard base is mounted in my table. It sports an ingenious macro-micro adjust. Holding in a spring loaded button disengages a rack that grabs a large spiral thread screw on the router. You slid the router in (up from under the table) to close to where you want to be and release the button. From there turn the micro adjust knob and lock in with a large lever. The whole process is extremely fast and easy. Milwaukee was late in coming to the combo market but they have pulled off some very solid engineering here.

+++PLUSES+++
*Very powerful and quiet.
*Excellent ergonomics, all controls are easy to reach and feel solid
*Macro/micro adjust is simple to use
*assembled in the USA

---MINUSES---
*this router comes with a T-wrench for above the table height adjust, I set it up under my tablesaw right wing so that the power switch, micro adjust and locking clamp face out. This puts the hole for the table top adjusting wrench under the fence. Not an issue for me, it's simple to reach under and give the knob a twist while I sight down the table.

*no spindle lock. The PW reviewer considers this a plus. This router has two huge nuts and nice fat cast wrenches for securing the collet. I personally hate the tiny spindle lock button on my pc plunger.

*solid price (for a solid router) there's plenty out there cheaper. I personally prefer to pay more for a solidly built tool I won't have to replace in a few years.

Milwaukee 5616-24 2-¼ Max HP EVS Multi-Base Router Kit Includes Plunge Base and BodyGrip Fixed BaseI found recently that my Porter-Cable Plunge Router had a slightly bent shaft. A new Armature/Shaft Assembly was $110.00 and several weeks to get, so I decided that the best course of action in order to be able to continue with my kitchen cabinets was to purchase a new plunge router. This Milwaukee 5616-24 KIt was an excellent choice. The P-C did not have a removable cylindrical motor assembly so it was a pain to install and remove it from my Bench Dog Router Table when I needed to use it freehand and I had to tie down the switch when using it as a table router. With the Milwaukee, I leave the fixed base on the router table and just switch the motor to the plunge base when I need to do freehand work. Also, since I am cutting numerous blind dados, the 1/8" step and repeat feature is great. Just set the bit on the work surface, set the depth plunger, then rotate the "step" beneath the plunger and cut an 1/8" at a time so you don't get chip buildup interference. The collet setup on the Milwaukee is better than the P-C. On the other hand, the P-C does have dynamic braking so it stops very quickly when it is turned off and it has a much better soft start feature. That said, the Milwaukee is a superior tool.