Shop Tested: Midsize Multi-Base Routers

Router combo kits promise the capabilities of a fixed-base and a plunge-base by combining both with a motor in a single, more-economical, more-compact package.

To find out if these dual-base kits can deliver on their promise of providing the best of both worlds, we ran nine models, all ranging from 1.75 to 2.3 horsepower, through their paces. Here's what we learned by examining their features and performance in an array of handheld and table-mounted tests.

An easily reachable switch makes using a router safer. Only the Bosch MRC23EVS places the switch on the handle of each base—our favorite approach—using a unique connection system, above. The other tested routers put the power switch on the motor. The Makita RF1101KIT2 and Metabo HPTKM12VC place their switch on top of the motor, so operating it requires letting go of one handle. The remaining routers with motor-mounted switches place them on the side within easy reach of a thumb or finger, a safer option.

To enhance bit-path visibility, the Bosch MRC23EVSK, Hercules HE041, and Skil RT1322-00 feature LED work lights. These shine toward the bit to greatly enhance routing-path visibility. The Bosch lights come on when you connect to power, doubling as a power indicator. Hercules and Skil power switches control their work lights. Both have separate lights that illuminate to show the router is plugged in.

The DeWalt DW616PK is the lone single-speed router in the group. All others feature variable speed. (See the chart, at the end of this article, for speed ranges.) A numbered dial, above, controls speed on all routers except the Skil.

It uses push-buttons and a digital display, above. While novel, setting speed using those controls proves more challenging than using a simple dial.

All but the single-speed DeWalt DW616PK have soft start—which brings the motor up to speed gradually to avoid a lurch at startup—along with electronic feedback to maintain motor speed under load.

Fixed-base features Bosch, Hercules, Milwaukee, and Skil motors travel straight up and down in their fixed bases and employ a threaded rod with a speed-nut mechanism for depth adjustment, above.

This requires an extra step for coarse adjustment, but we prefer this system because it keeps the switch in the same location relative to the base, above.

Makita and Metabo achieve depth adjustment with spiral-grooved motors that rotate in their bases. This allows uninterrupted motor adjustment through the entire range but changes switch location relative to the base, above.

The DeWalt routers also feature spiral-grooved motors, but a rotating ring on the base mates with the grooves. Turning the ring raises and lowers the motor without the motor rotating. DeWalt's depth-adjustment ring incorporates an indexing ring, which proved difficult to grip and turn. On the Makita, locking the motor into place made turning the indexing ring difficult, which hindered zeroing the cursor for subsequent fine depth adjustment.

We formed five edge profiles with each router, making individual passes at one-third, two-thirds, and finally at full depth. All routers felt comfortable in our hands, vibrated little, and performed equally well in this test.

Switching to a 3/4" straight bit, we set up each router to form 1/4"-, 3/8",- and 1/2"-deep grooves and dadoes. We set the cutting depths using each router's onboard depth-setting features, then measured the actual depths. Once again, all routers performed well. We measured maximum depth variations of around .014", about the thickness of three sheets of copy paper.

All of the plunge bases feature a lever that engages and disengages the plunge mechanism, letting you plunge, then lock the bit position at the desired depth. Spring-loaded levers on both Bosch routers, as well as on the Makita, Metabo, and Milwaukee, release when you press the lever down, allowing you to plunge, then lock when you let it go.

Both DeWalt routers, the Hercules, and Skil are opposite: Pull up to release and plunge then push to lock in position.

We prefer the former because pushing the lever to activate the plunge action (the base's defining purpose) feels more natural, above. During one test, the DW616 lever vibrated loose due to bit chatter. The Metabo's plunge action felt sticky and its return action was sluggish.

Except for the Bosch and Milwaukee, above, we found most plunge scales difficult to read and set accurately. Scales cast into the Hercules and Skil bases provide little visual contrast. For best results, we advise setting bit depth using setup gauges or a measuring device.

We like turret stops with lots of steps and question the usefulness of adjustable ones, above. The Bosch 1617EVSPK turret features seven steps at fixed 1/8" increments. The Bosch MRC23EVSK has the same turret, but two adjustable steps interrupt the even progression; this is not an improvement in our book. Turrets on the Hercules and Skil wobble when pressed down by the plunge-depth rod, making accurate adjustment dubious.

All plunge depth-stop rods except the Metabo's incorporate fine adjustment. A unique Bosch MRC23EVSK feature allows fine adjustment after locking coarse plunge depth into place. The Makita threaded plunge-stop rod incorporates a speed-nut mechanism so it doubles as coarse and fine adjuster. Milwaukee's versatile plunge-depth rod features rack-and-pinion operation with a fine-adjustment knob as well as a speed-nut mechanism for coarse adjustment, a very thoughtfully engineered feature.

Using turret stops and depth rods, we set up each router to form 1/4"-, 3/8",- and 1/2"-deep grooves and dadoes and measured the actual depths. All but the Hercules and Skil made cuts within .009" of the target. Wobbly turrets and out-of-flat bases on those two routers likely caused variation up to .039".

Switching to a 1/2" straight spiral upcut bit, we routed 1-1/2"-deep mortises, starting at 3/8" deep and proceeding in 3/8" steps. Although all mortise depths were within .010" of the target, the cursor on the Makita plunge rod slipped during progressive plunges and required re-zeroing.

To test stop slippage, we plunged 25 holes 1" deep with each router and measured every fifth hole. No router showed significant slippage, but the out-of-flat bases of the Hercules and Skil rocked slightly on the upstroke. This caused tear-out as the bit caught the edges of the holes on exit. Shimming the subbases with masking tape eliminated the problem.

With two wrenches, both Bosch models, the DeWalt DW616, Makita, Metabo, and Milwaukee generally provide easier bit changes than the remaining routers equipped with an arbor lock and single wrench. Opposing wrenches eliminate the wrestling match sometimes encountered when depressing the arbor lock and holding the motor with one hand while turning the wrench with the other. On the Makita, a skinny arbor nut and thin, stamped wrenches combined to make holding the wrenches in place difficult.

Dust shields and ports on fixed bases block bit-change access, so it's best to install bits with the motor out of the base. The 3-1/2" panel-raising bit used in the power test (see Pushing for Power, next page) didn't fit through the Makita, Metabo, and Milwaukee fixed bases.

Through-the-post dust extraction on both DeWalt plunge bases, above, proved extremely effective. Snap-in shields on the Hercules and Skil totally enclose the fixed bases, and shrouds on the plunge bases surround the bit. Both work extremely well with normal router shavings, though larger splinters easily plugged the fixed-base port and the neck restriction in the plunge port. The Milwaukee port did an excellent job, fits both bases, and features tool-free installation.

The fixed bases of both Bosch models, as well as the Hercules, Milwaukee, and Skil, enable through-the-table bit adjustment. We found height adjustment easier and more accurate with these routers. All but the Hercules and Skil include height-adjustment wrenches.

When mounted in a table, depth-adjustment rings on the DeWalt routers tend to bind when turned with one hand, so you have to reach under the table with both hands. The digital display and speed controls on the Skil face down when table-mounted.

Measuring the power of a router proves challenging. That's because feed rate makes a big difference. If the router begins to bog down, you'll naturally slow your feed rate, whether you're routing handheld or with a table. Because of that, we knew we'd never be able to move the routers or the stock at the consistent rate required for an apples-to-apples test.

So, we came up with the router-table rig, above. We mounted each router in its fixed base and installed each one in the table using an identical phenolic insert plate.

To take feed-rate inconsistency out of the equation, we mounted a power feeder and ran the stock at 6 feet per minute—an aggressive rate we knew would tax the motors.

To further tax the routers, we installed a fresh Freud 3-1/2"-diameter panel-raising bit in each router and adjusted the no-load speed as close as possible to 12,000 rpm. (No router locked in at the exact speed indicated by the settings.) Cutting the full profile in three progressive passes, we checked router rpm and amp draw. Then we ranked routers according to how far the speed dropped from the initial setting and whether amp draw exceeded motor ratings. We measured motor housing temperature before and after each cut.

With the most power, innovative handle-mounted switches, LED work lights, and through-the-base adjustment for table mounting, the Bosch MRC23EVSK proves hard to beat, unless you consider the Milwaukee 5616-24. Its well-engineered features place this router toe-to-toe on power. It also offers through-the-base adjustment, a body-grip fixed base, and dust collection. We award Top Tool honors to both, below. 

With all but the Hercules and Skil closely packed price-wise, we give Skil, below, with adequate power and better features than some of its pricier competition, the nod for Best Value.