DW-621 Offset Subbase

To avoid proximity of the offset plate knob and the left control ball knob I made the plate long, (10-5/8"). The spindle of the 621 is offset one inch closer to the right ball knob. These 2 factors situate more than 2/3 of the offset subbase on the work while on end or edge cuts. The stability of the router/subbase ensemble is such that you'll forget it started out in the handicapped parking place.

The plate is drilled on five 1" centers for easy hole and disk making. The 3/16" pin (supplied) is in the first (2" radius) hole. Seat the pin in a 3/16" hole in the work and you can rout a perfect circle from setup to finish in a minute or two. Note the plate surrounds the entire router. Drop the guy and it will hit the plate, (not the router), and distribute the impact to the casting, saving the router for another day's work.

The 621 can hit target depth on the first shot. Remove the turret and let the pencil depth adjuster index off the anvil as shown. A screw through the barrel will lock the fine-adjust. The adjuster will work without the pencil should you not want to drill and tap for the brass screw (supplied, round head 8-32 x 1/4"). To hit target depth: Gently plunge the cutter to the work surface and lock the motor. Lower the depth adjuster on a spacer (drill shank, feeler gage, gage block etc.) and lock it. The router will plunge to this depth, no more guessing.

My 621 plate is supplied with either of 2 cutter holes. The counter bored hole (rear) is pre-milled for the PC/DW collar guides. The 1-3/4" cutter hole plate (foreground) is about the safe diameter limit for cutters in a hand router. The 12mm thick acrylic subbases are completely machined, assembled, supplied with all hardware, and can be installed in 30 seconds. The tool is made and was designed expressly for the DW-621; it is not a one-size-fits-all after thought. The plate will not bend or deflect with time or use.

I cut a couple of rings here. To keep the rings or disks from breaking lose and self destructing when the cutter goes through the work, rout~1/64" or so short of full thickness. Then band or jig saw out the pieces and flush trim the 1/64" flash. When using a 1/4" cutter in the 621 (and 3/16" pin) expect holes produced with the Warner subbase to = 4", 6", 8", 10" and 12". The disks will be 1/2" smaller. As an extra, I can custom drill a 3/16" pivot hole for any circle (hole or disk) from ~1-7/8 to 13". Note the excavation on the edge of the work; that was the test for the nest in the next picture.

The "fit" for metal and wood has got to be close. Overshoot the depth and you may have lost the work. Too shallow and you'll sand metal 'till hell freezes, a job that's 10 X harder than sanding wood. I got the depth right on the first shot with the 621 using the metal bar itself as the depth gage on the anvil. The offset subbase surface is so generous the router will not tip and spoil the excavation.

In full compression there is still plenty of access to the offset subbase knob. You'll have complete control on single depth edge cuts (typical fixed base router work) or cuts around corners. An ordinary round base router will have less the 25% of its casting on the work rounding corners; impossible to keep flat. Let the 621 Warner Offset Subbase extend the application of your 621 for both fixed and plunge functions without compromise.

I've designed and now make an offset subbase for the DW 621 plunge router. This router, in my view, is now the friendliest and most useful router in my inventory. Its unusual base casting, with its cutter hole off-center, has been a hell of a challenge to use as a plunger, let alone as a fixed base doing single depth edge cuts. With my offset subbase it's as good as the best of fixed base routers and more agile. The 621/Warner-Offset Subbase ensemble can now substitute nicely for one of the PK's (plunge and fixed base packages with one motor to be traded between the two castings), and is the answer for the guy who wants only one hand router. (On inside cuts, as a plunger in the mid-power range, it will zip along nicely without tipping, donned with my round plates).

The 621 has the best plunge action, and for me, the best hand ergonomics of all routers. Its controls are concentrated in its 2 armored ball handles. You can plunge, lock, start the motor, steer, and stop with your hands always on the control knobs; safety right in your face. Moreover, with the 621, you can hit target depth of cut (with some minor modification) in one shot. The time and material saved by getting it (target depth) right the first time is more than enough justification for the exploitation of this tool. It would be criminal to ignore the utility and facility of this masterpiece of routerdom because of its unwieldiness. With my subbase on this tool, you won't be charged with any misdemeanors.

My offset subbase is not a casual after thought. It has taken months to design, fixture and test. It is a precision tool, taking more than 30 operations to make and countless quality checks and inspections. I am the sole fabricator; the product is not farmed out.

In addition to providing the 621 with a power steering unit, expect the offset subbase to render visibility of the work, provide the same facility as a fixed base router, and stabilize the router on inside or outside corners. Moreover, the plate is milled for PC/DW collar guides or is supplied with an optional 1-3/4" cutter hole for larger or bearing guided cutters. For the speaker makers and others needing precision holes or disks, the plate is drilled and designed for circle making.

A 3/16" steel pivot pin is supplied to facilitate making holes of 4", 6", and 8", 10", and 12" diameters. The plate is drilled 5 times on 1" centers such that when using a 1/4" cutter and the pivot pin you can rout the even numbered (inch) holes as indicated. Several hole samples from my setup were within +or- .003" of target. Disks will measure 1/2" less in diameter than the corresponding hole using a 1/4" cutter as the hole maker. Bigger, smaller or reground cutters will shift these values. Custom drilled pivot holes are an option for that special sized hole or disk.

For circle making: Drill a 3/16" hole in the work, insert the pin in the work or templet and fit the other end of the pin in the desired pivot hole in the subbase. Circle rout in shallow passes (<3/16") to within 1/64" of the work thickness. Saw out the disk and flush rout the 1/64" flash from both the hole and disk. The procedure takes only a minute and unlike band-sawn circle making, you get a useful and continuous un-sawn hole. Making just one precision hole could pay for the subbase in time saved.

Concerns about collar/cutter centeredness: See the Collar Guide and Sundries links.

Product Options

The following are the product options and prices. Freight (UPS Ground), handling, packaging, assembly, and all hardware are included. There will be 5$ added to Canadian, Alaskan and Hawaiian customers for USPS Priority or Air Parcel Post. Material for the offset plate is 12mm acrylic; round plate material is Ľ" acrylic.