Mighty Minis

{ product review } mighty minis Originally the tool of choice of kitchen installers for trimming laminate countertops, mini-routers are earning an important role in today’s woodworking shop for handling a variety of common light routing tasks.

by mar k goodall

Porter-Cable 310

Porter-Cable 7310

DeWalt DW670 Ridgid R2400

Bosch PR20EVS

THERE ARE TWO KINDS OF WOODWORKERS: THOSE WHO BUY TOOLS BECAUSE THEY NEED THEM AND THOSE WHO BUY TOOLS BECAUSE THEY WANT THEM. Here’s a tool that appeals to both – inexpensive enough to own several, as well as being very useful. I’m talking about laminate trimmers, those mini-routers we are seeing more of these days. For many years – back when they were simply called trimmers, not routers – there were only a few available. Now, just about every manufacturer makes at least one model. Manufacturers refer to them by a number of names: trimmers, laminate-trimmers, trim routers and palm-grip routers. Whatever you call them, these handy (pun intended) one-handed, ¼" collet mini-routers are great. A mini-router isn’t the best choice for your first router, but it complements a full-sized one in many ways. Understand that these mini-routers won’t take the place of a more powerful, accurate and stable (larger) router, and using any tool for a task it wasn’t designed for can be dangerous. What follows is a roundup of eight mini-routers you’re most likely to find on your favorite store’s shelves. The DeWalt DW670, Porter-Cable 310 and Porter-Cable 7310 have been around for some time, while the Freud FT750 and Makita 3707FC are fairly recent introductions. Three are quite new: the Bosch Colt PR20EVS, Ridgid R2400 and Ryobi TR45.

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Laminate trimming can involve more than just Freud FT750 quickly and neatly cutting Makita 3707FC off the laminate overhang. Trimmers with extra bases and offset attachments can handle the more advanced laminate trim-ming tasks that countertop installers would face. Because of their affordability and availability, I expect we’ll see more mini- routers doing woodworking chores in our workshops Ryobi T45 than trimming laminates for countertops, especially since more countertops

are being made with solid- surface materials like Corian Although some models receive consistently high marks instead of laminate. from both professionals and DIYs, there isn’t one perfect mini- router. Some woodworkers prefer the size, shape or features of Power, speed and volume one model over another. These models range from 4 to 6.5 amps with the Porter-Cable For example, if you’ll use one for edge-trimming laminate 310 and the Ryobi drawing the lowest current, and the Freud material like Formica, you may not need the micro-height and the Ridgid drawing the highest (see comparison chart, adjustment feature found on some models. Similarly, if you page 80). Surprisingly, performance wasn’t affected by the plan on having several mini-routers, each for a dedicated task difference in power as much as I expected. While with a bit that is “set and ready to go,” you may not appreciate the DeWalt, Freud and Porter-Cable 7310 felt the strongest, the features that facilitate bit changing. But if you plan to have just 310 didn’t feel as underpowered as its amp rating might one mini-router and swap bits like you do with your full-size indicate. All had enough power to handle the tasks that 1 1 3 machine or if you’ll use it for more precise routing work where included cutting a /4" groove, as well as /18" and /16" fine bit-depth adjustment is necessary, those features will be roundovers in red oak and maple. key. The Ridgid and the Bosch were the only two variable-speed The newer models boast features such as soft-start, variable units tested. The Bosch, Makita and Ridgid all have a soft-start speed, and better ergonomics but the older models are still feature that greatly reduces the kick upon startup. When very good choices and are better in some areas. starting, the Ryobi had the greatest torque effect – if I hadn’t Mini-routers themselves aren’t entirely new. Small rout-ers tightened my grip it felt like it might spin out of my hand. The of less than 1 hp, like the Porter-Cable 100, have been around others lacking soft-start had a similar twisting force, although 7 for a long time. This /8-hp router was the vener-able 690’s first not as abrupt. As expected, the Bosch and Makita had very little little brother. Laminate trimmers have been around for almost torque effect due to their soft-start electronics, and the Ridgid as long as laminate has. But while the Porter-Cable 310 and had almost none. The Ridgid’s soft start is the slowest and others may have been around for several decades, what’s new smoothest by far, noticeable both to ears and hands. It’s slow is the number of models now available that offer good enough that I had to hold back a second before starting to cut, performance and high-end features for under $100. waiting for it to hit full speed. Since precision, especially in height adjustment, isn’t that Both the Bosch and Ridgid boast electronic speed control, critical for laminate trimming, all models tested do well for but frankly I didn’t feel any of these routers slow down even 3 these simple tasks. In some cases, there is more preci-sion built when cutting oak with a dull /16" roundover bit. I suspect that if into adjusting the roller/bearing guide attachment on these you push one of these enough to need electronic speed control, tools than the height. your task needs a full-size router. As to noise, there’s a noticeable difference between the

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quietest (Makita) and the loudest (Freud and DeWalt). Speed ing motor housing, base and sub-base. The Freud and Ridgid contributes to noise, so the faster routers produced the highest both have plastic motor housings, but aluminum bases. The pitched noise. From quietest to loudest, the order went – Bosch, DeWalt, and Porter-Cable 7310 have alu-minum bases Makita, Ryobi, Ridgid, Bosch, Porter-Cable 310, Porter-Cable and motors whose lower halves are made of aluminum and 7310, Freud and DeWalt. Keep in mind that the variable speed upper halves of plastic. The Porter-Cable 310 is made almost Bosch and Ridgid become the quietest of all when set at their entirely from aluminum. I prefer aluminum over plastic for its lowest speeds. durability and precision, especially in the base and lower half While some may question the need for variable speed in a of the motor where flex and heat expan-sion can affect mini-router, the biggest advantage is to reduce the noise if you precision of any fine adjustments. don’t need full speed. But you should wear The Makita and Ryobi are the lightest and easiest to grab ear protection, since each may be loud enough to cause off the shelf. The extra heft of the others, however, isn’t nec- hearing problems over time. essarily a negative as it contributes to stability and durability. The Porter-Cable 310 is the second heaviest (behind the Construction and weight Freud), and the most solid and steady. I know firsthand that it 1 These mini-routers, like their bigger cousins, consist of three can sustain a fall from 3 /2' onto a concrete floor with no ill basic parts – motor, base and sub-base. The sub-base on effects. Although the plastic bodies on the others may to be all models tested is plastic or phenolic, so they won’t scratch the able to take similar abuse, I’m not sure the plastic bases of the work surface. The phenolic sub-bases seemed to be flat-ter than Makita or Ryobi would. the molded plastic ones, but all were within 0.004". The bases of these mini-routers are made of aluminum or plastic, while Height adjustment motor housings are made of aluminum, plastic or a For single-task use, just about all these models will work combination of both. well. But when faced with a routing task demanding The Makita and Ryobi are made entirely of plastic, includ- precision and critical height adjustments, I’d grab one that

No- Material Hole size Soft 1 Circum- Sub-base Fits P-C Spindle Power Cord Flat Power switch Replaceable Collet Bit Straightedge Make/model Amps load Height 2 Weight Base/ Sub- 4 Brushes Warranty Made in start ference Motor shape & size Base bushings lock cord length top type/location collet wrenches included guide RPM Sub-base base 1 drop Bosch 16,000- 1 plastic & aluminum/ square* 9 9 3 30 days/ 5.7 yes 7 /2" 9" 3.3 lbs 3 11 1 /16" 1 /16" no yes side 10' 5" yes side/rocker external yes Malaysia forged17mm no yes PR20EVS 30,000 aluminum plastic 3 /8" x 3 /16" 1 year wrench

DeWalt 3 5 plastic & aluminum/ square* 3 5 90 days/ 1 wrench 5.6 30,000 no 8 /16" 8 /8" 3.6 lbs 1 5 1 /16" 1 /8" yes yes top 9' 6" no side/slide internal yes Italy no no DW670 aluminum phenolic 3 /2" x 3 /8" 3 years 17mm 2 wrenches Freud 1 3 aluminum/ rectangular 5 1 6.5 27,000 no 10 /2" 8 /8" 4.4 lbs plastic 13 7 1 /16" 1 /8" no no top 7' 6" no side/slide internal yes 1 year Spain 13mm & no no FT750 phenolic 2 /16" x 3 /8" 17mm 2 wrenches Makita 3 plastic/ square 3 3 4.4 26,000 yes 8" 7 /4" 2.6 lbs plastic 1 1 /8" 1 /8" no no top 8' 4" no top/toggle external yes 1 year Japan 10mm & no optional 3707FC plastic 3 /2" 17mm

Porter-Cable 5 3 3.75 aluminum/ round 3 30 days/ 2 wrenches 4.0 27,500 no 5 /8" 10 /8" aluminum 1 /16" 2" yes no side 7' yes side/slide internal yes USA 7 11 no no 310 lbs phenolic 4" 1 year /16" & /16"

Porter-Cable 3 7 3.75 plastic & aluminum/ rectangular 3 3 30 days/ 1 wrench 5.6 30,000 no 7 /8" 8 /8" 3 5 1 /16" 1 /8" yes yes side 10' yes side/slide internal yes USA 11 no no 7310 lbs aluminum phenolic 3 /8" x 3 /8" 1 year /16" 2 wrenches Ridgid 20,000- 3 7 3.65 aluminum/ round 3 1 90 days/ 6.0 yes 7 /8" 7 /8" plastic 1 1 /16" 1 /2" yes no side 12' 4" no top/toggle external yes China 10mm & yes yes R2400 30,000 lbs plastic 3 /2" 3 years 17mm 30 days/ 2 wrenches Ryobi 3 1 plastic/ square 7 7 no (base has 4.5 25,000 no 6 /4" 8 /2" 3.0 lbs plastic 1 1 /16" 1 /16" no no side 10' 4" no top/slide internal no 2 years China 10mm & yes TR45 plastic 3 /2" holes for one) + lifetime 14mm 1height measured at its lowest setting 2circumference measured at most convenient grip position *these bases are almost square 3has notch on spindle for use with second wrench (not included) instead of spindle lock, if preferred 4flat top allows router to sit upside down for changing bits

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can be adjusted accurately. you turn the height adjustment ring on the Porter-Cable When considering height adjustment, I considered both 310, or the thumbwheel on the Bosch, you can translate the how quickly and accurately adjustments can be made. The amount turned into a height change, but frankly I find that motors on the Makita, Ridgid and Ryobi simply slide up and too complicated. Regardless of which router used, down inside their bases, making major height adjustments I still measured bit height by hand if any accuracy was fast and easy, but fine adjustment difficult. The Makita has a required. small thumbwheel for fine-tuning the height, but it’s not as Speaking of height, a router’s center of gravity affects precise as the threaded-screw height adjustment found on how stable it feels in use. A tall, top-heavy router feels more the DeWalt and Freud. Those use a screw and thumbwheel likely to tip than a shorter one, something we see in full-size that provide fine adjustment, but slow major height changes machines when comparing a fixed-base router with a taller considerably. plunge router. The same is true with a mini-router, but The Bosch and Porter-Cable 7310 are the only two that because of its smaller base and footprint, the effect can be do both, eliminating the compromise between quick and more pronounced. Some, like the Freud and DeWalt are tall accurate. Each has the ability to adjust height with and feel like they will tip sometimes, especially when held a quick slide of the motor. With the Bosch, a slight turn higher up on the housing. Others, like the Porter-Cable 310 of the motor in its base engages the fine-adjustment and Ryobi, are shorter and feel more stable. The heights of 1 thumbscrew. With the Porter-Cable 7310, tightening the these mini-routers range from a tall 10 /2" on the Freud to a 5 thumb knob engages the fine-adjustment screw. diminutive 5 /8" on the Porter-Cable 310. Easy-to-read height scales are present on the Bosch Height was measured from the bottom of the sub-base to 1 1 ( /16" and 1mm increments), Makita ( /8" increments), and the top of the motor with the routers at their lowest setting. 1 1 Ridgid and Ryobi ( /16" increments) units. They give a good All are about 1 /2" higher at their highest setting. estimate of height, but aren’t accurate enough to be relied upon for anything more than rough measurement. When

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Ergonomics, comfort and grip You change bits on these mini-routers much the same way you do on full-size routers. All come with either one or The most comfortable mini-routers are the ones that can be two (as required) wrenches to loosen and tighten the col-let grasped easily, and the router’s diameter is one fac-tor nut. Models that require two wrenches have a second, smaller related to its ergonomics, as well as its shape. Since not all wrench that fits on the “flats” of the spindle, keeping it from mini-routers have completely cylindrical bodies and bases, turning while you turn the wrench on the collet nut. it’s difficult to measure their diameter accurately. Instead, I’ve measured the circumference of each router at the point where they’re designed to be held. I found the smaller Makita, Ridgid and Ryobi the easiest to grip. The Ridgid is the most comfortable, but all three are very easy to hold comfortably and securely. The Bosch and Porter-Cable 310 are the largest. I can’t quite get my hand completely around them, but they’re still very comfortable to hold. Keep in mind that comfort is subjective, so this is one place where measurements and charts aren’t nearly as valuable as hands-on testing. Someone with larger hands may feel cramped on the smaller Ridgid and prefer the larger body of the Bosch. The Bosch boasts a soft rubber grip and golf- ball-like dimples for better grip. It’s very comfortable when held high up, but I found it a little too high. When held lower for stability, it’s too wide. Knobs and bumps can get in the way on some of these mini- routers the lower down you hold them. This is less of an issue with the Porter-Cable 310, Ridgid and Ryobi. The Freud has a comfortable, but very high grip. MOST MINI-ROUTERS, like the Porter-Cable 7310 shown here, offer a variety of bases and sub-bases for different tasks. Power switches The switches on all models tested are plastic. The switch on the The Bosch, DeWalt and Porter-Cable 7310 all have a Makita, Ridgid and Ryobi is on top; the Bosch, DeWalt, Freud spindle lock that lets you loosen or tighten the collet nut with and Porter-Cable routers have theirs on the side. All can be one wrench. These locks are spring-loaded so you must hold operated easily this way. The one exception is the Freud, with a the button in one hand while using the single wrench in the switch close to the bottom of the motor that felt clumsy. other – in other words, you use only one wrench, but still use The toggle switches on the Makita, Ridgid and Ryobi, and two hands. the Bosch’s rocker switch are the easiest to use. The The Bosch has “flats” on the spindle allowing you to use a rest had slide-switches. Only the Ryobi has a bright red color on second wrench (not included) instead of the spindle lock if you the switch to indicate when the switch is in the “on” posi-tion, prefer. This turned out to be a good thing, as I found the push making it easy to determine the switch position. The Freud button on the Bosch hopelessly difficult to use. I had to push switch was also easy to see. The Makita, DeWalt and Bosch all the button at precisely the right angle and then push it in have switches that are fairly easy to read, but I found myself further than was comfortable. It was easier using two wrenches. having to double-check switch position on both Porter-Cables The DeWalt also has flats on its spindle allowing two-wrench before plugging them in. changing if preferred, but the spindle lock must be completely removed to reach them. The Porter-Cable 7310 doesn’t have Bit changing accessible flats on its spindle so you have no choice but to lock Depending on your philosophy and number of routers you the spindle. It’s not as comfort-able as the others, but it was the have, the ease of bit changing may be of greater or lesser easiest and most effective of all three. importance to you. Changing bits on all these routers is fairly There isn’t a whole lot of room for wrenches in most easy, but if your goal is to have a dedicated router for the bits of these mini-routers. Makita makes it easier by providing you commonly use, you might not change bits often enough to thinner and longer wrenches. While it’s possible to change the appreciate the different features to make it easier. bit on all these mini-routers without removing the base,

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there isn’t a lot of room, so often it’s quicker and easier just to All these mini-routers come with standard bases, but the remove the motor. Two models excel at this: Simply pull the Bosch, DeWalt, Freud and Porter-Cables have additional motor on the Porter-Cable 310 until two clips release, or turn a bases that can either be bought separately, or come in a more lever on the DeWalt to pull it off its base. The Bosch, Makita expensive kit configuration. The Bosch has an available tilt and Ryobi are almost as easy: After loosening the barrel/collar base. The DeWalt and both Porter-Cables have an offset clamp you pull the motor to its highest setting, twist and pull. A stop-block prevents the Ridgid’s motor from being completely removed, so you’d have to remove the thumb knob and screw in order to remove the base. With the Freud, you’d need to use a T-20 driver to loosen its base, but it’s not worth the trouble. Freud’s base, like the Porter-Cable 7310, is very open so there’s enough room for wrenches. Like full-size routers with a flat top, the Bosch, Porter- Cable and Ryobi mini-routers can sit upside down while changing bits. All but the Ryobi have a replaceable collet separate from the spindle. I was surprised to see the new Ryobi has the same integrated spindle collet as the previous model. It was criticized in the past because if the collet gets damaged, it can’t be replaced. I found no noticeable difference in ease of inserting or removing a bit from any of the collets tested. In fact all were a little tight and none were noticeably self-eject- ing. The Bosch has a nice feature: Its collet is held inside the collet nut and won’t come out and be lost or damaged when you remove the nut. Base and sub-base These mini-routers have a base that holds the motor, and a replaceable sub-base that attaches to its base. The smaller bases offer better visibility of the work and can get deeper into corners, but at the expense of stability. The clear bases of the Makita and Ryobi offer good visibility, but perhaps at the expense of durability. The motor mounts to its base in one of two ways. The motors on the Bosch, Makita, Porter-Cable 310, Ridgid and Ryobi sit inside a one-piece base completely surrounding the ALTHOUGH ORIGINALLY DESIGNED (and named) for the motor barrel, just like a full-size router. The DeWalt and Freud task of laminate trimming, these small routers lend themselves two-piece split bases clamp around the bottom of the motor. well to dozens of chores in the woodshop. The Porter-Cable 7310 one-piece base attaches to the side of its motor. base, a seaming base and a tilt base. The Freud has an The Makita and Ryobi have a transparent plastic base. The offset base, a plunge base and a tilt base . The Ryobi comes with Ryobi’s trademark yellow-tinted transparent plastic base is an additional two-handled woodworking sub-base. good, but the clear base and dual LED work lights give the A laminate installer would probably appreciate the option-al Makita the best visibility of the work surface. bases more than woodworkers. All these mini-routers have a plastic or phenolic sub-base that can be removed and replaced. Edge guides and bushings Listed on the comparison chart on page 80, you’ll see the There are two types of edge guides found on these mini-routers: a diameter of the hole in the base as well as the sub-base. Use straightedge guide, similar to the type used on this to determine the maximum diameter bit that will fit in the full-size router, as well as a roller-bearing guide, which comes router. Remember, however, that just because a bit fits doesn’t from the tool’s original use of trimming laminates. make it safe to use. A straightedge guide holds the mini-router at a certain

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distance away from edge of a straight workpiece. Only the None of these points are that important; they just indicate Bosch and Ridgid include this type of guide. The guide on the that there’s always room for improvement. Bosch attaches to the side of its base, while the Ridgid’s guide I suspect that with this new breed of routers, each manu- slides and clamps onto two steel rods screwed into the holes in facturer will look at its competition and may include a few new the base. The Ryobi base has similar threaded holes, but features on their next models. Unless there’s a patent issue, I doesn’t come with an edge guide. expect the dual-mode height adjustment found on the Bosch A roller-bearing guide attachment replaces the function of and the Porter-Cable 7310 may be seen on other mini-routers a pilot bearing found on many router bits, allowing you to use in the future. a non-pilot bit the same way. All except the Ryobi come with a Likewise, the bright dual LED work lights on today’s Makita roller-bearing guide attachment. The Bosch, DeWalt, Makita may be seen on other routers in the future. It’s such a nice and Ridgid attach to the side of the base and extend down feature I’m surprised more don’t have it below the sub-base. Both Porter-Cables as well as the Freud have an attachment that screws directly into the bottom of the Summary sub-base. While it comes standard with the Freud, it’s an All of these little routers are a pleasure to use. For a true mini- optional accessory for both Porter-Cables. router, I prefer the Porter-Cable 310 or the Bosch for their If you want to do inlay work, you’ll want a mini-router more precise height adjustment, but for a “set and ready to go” with a sub-base that can accommodate router bushings or mini-router, all of those tested do a great job. template guides. The Porter-Cable style bushings that screw Those of us with $150-$200 in our pockets looking to onto many full-size router sub-bases can also be used on some purchase our first all-purpose router should look at a full-size of these mini-routers. Those standard bushings will fit the router first. As handy as they are, mini-routers lack the power DeWalt, Ridgid and Porter-Cable machines right out of the and versatility found in a full-size machine. Unless your work is box. You can get an optional sub-base for other models, like specific and small-scale, you may be disappointed. But a mini- the Bosch, that will accommodate a bushing guide. The router would be a welcome addition as a second router. I have had four of these mini-routers, along with six full-size routers Makita comes with its own single pressed-steel template guide, over the last four or five years and more often than not, when which doesn’t offer the versatility or precision that the I’m reaching for a router for a quick small task, I’ll reach for a multisized machined brass bushings do. 3 mini-router with a bit that’s all set and ready to go. I keep /16" 1 1 and /4" roundover bits as well as a /4" flush-trim bearing bit 1 Small features ... and some small quirks and a regular /4" bit in each of my minis. Some features are functional while others are just frills. At $150 the Porter-Cable 310 is the most expensive, but I The orange LED on the Ridgid’s power plug, designed to appreciate the solid performance and accuracy it gives. Every indicate whether or not the router is “live” (plugged into a other mini-router here is priced at, or under, the impor-tant outlet or extension cord that has power), would be more $99 price point for the single-base router . The Bosch and useful if it was on the router itself rather than up to 10' away at DeWalt and the Porter-Cable 310 and 7310 also come in kits in the wall. Compare that to the dual LEDs on the Makita that the $200 range that include the extra offset and tilt bases. light up when the machine is running, which is a great feature. Unless you have a specific need for them, you may prefer to Even better would be a LED work light that turned on when spend the additional money on yet another mini-router the router was plugged in, acting both as a “live” indicator as instead. well as a work light. I would rate each of the routers tested as good, very good or excellent: however, because I did not find a router with all the features available on the individual routers, Mark Goodall I can’t say any one is perfect. The Porter-Cable 310 lacks soft-start. The Bosch’s com- Mark Goodall is a self-admitted fortable grip is wide, but its pressed-steel height adjustment tool junkie and DIY who lives in barrel clamp looks out of place on a tool with more refined Peachtree City, Ga., with his wife features. Compare that to the nicely curved, thick and com- and three young children. He’s been fortable cast aluminum clamp on the Ryobi, and you’d think woodworking since he was 12 years they were mismatched. However, you must disassemble the old, and now works as an IT consul- Ryobi’s base to remove the retail store’s anti-theft device glued tant to pay for his woodworking hobby. His Web is inside. www.happywoodworking.com.

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Safety and limitations As useful as they are, these one- handed routers don’t take the place of a solid and stable two- handed router. A mini-router used for the wrong task can quickly become a wild, flying, flesh-eat- ing animal. The rotational forces involved with a blade spinning at 30,000 rpm increase as the diameter and bite of the bit increase. Even with anti-kickback bits, it’s possible to push a router too hard, have the bit catch the work surface and then spin out of your hand. This isn’t likely to happen on a full- size, two-handed router which offers a much firmer grip, but when you’ve wrapped your hand around a mini-router – especially if you don’t have large hands – it’s amazing how easily it can twist and jerk right out of your hand. Then as it is performing its twirling destructive dance all over your wood or workbench, you’ll be hard-pressed to react safely. A mini-router is great for light routing tasks, but it’s not a full- size router and can’t be expected or pushed to do everything you could with a larger router. Remember, the right tool for the job is always the safest tool for the job. Use a mini-router only with small-diameter bits, and take multiple shallow passes. Try to cut too much, too fast and you might have it fly out of your hand and out of control. Avoid the temptation to use your other hand as a workpiece clamp too close to the router. Finally, don’t overestimate your one-handed grip – it’s not as firm as your grip on a two- handed router. —Mark Goodall

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