Plunge Routers

About Plunge Routers

Plunge routers are essential woodworking power tools designed to create precise grooves, profiles, and decorative edges in timber and sheet materials. Unlike fixed-base routers, plunge routers feature a spring-loaded base that allows the cutter to be raised and lowered vertically during operation, giving you complete control over cutting depth and making them ideal for stopped cuts, inlays, and template work. When not in use, the cutter retracts safely above the workpiece, reducing the risk of accidental contact and making these machines inherently safer than their fixed-base counterparts.

Modern plunge routers are available in both corded and cordless formats, with popular manufacturers including Makita, DeWalt, Festool, Bosch, and Trend offering machines to suit every budget and application. The key distinction between models centres on collet size – typically either 1/4" or 1/2" – with the former being more compact and manoeuvrable for intricate work, whilst the latter provides greater power for demanding applications like kitchen worktop jointing and heavy-duty edge profiling. Many premium models feature variable speed control, soft-start motors, and compatibility with guide rails for enhanced precision.

Whether you're a professional joiner working on site, a kitchen fitter installing worktops, or a DIY enthusiast tackling home improvement projects, investing in a quality plunge router opens up a world of creative possibilities. From cutting housing joints and hinge recesses to creating decorative mouldings and template routing, these versatile machines are indispensable for anyone serious about woodworking.

Jargon Buster

• Collet Size: The diameter of the tool holder that grips the router bit shank. UK routers commonly use either 1/4" (6.35mm) or 1/2" (12.7mm) collets, with some machines offering interchangeable collets for flexibility.
• Plunge Depth: The maximum distance the router bit can travel vertically into the workpiece, typically ranging from 40mm to 80mm depending on the model. Greater plunge depth allows for deeper cuts and more versatile applications.
• Variable Speed Control: An adjustable dial or electronic control that allows you to alter the RPM (revolutions per minute) of the router bit, typically ranging from 10,000 to 24,000 RPM. Lower speeds suit larger diameter cutters, whilst higher speeds are ideal for fine detail work.
• Soft Start: A motor control feature that gradually increases the router's speed when switched on, reducing torque reaction and preventing sudden jerking movements that could compromise accuracy or safety.
• Guide Bushes: Circular metal rings that fit around the router bit and run against templates or guides, allowing accurate pattern replication and edge following whilst maintaining a consistent offset distance.
• Brushless Motor: A more efficient motor technology found in modern cordless routers that delivers longer runtime, reduced maintenance requirements, and improved power-to-weight ratio compared to traditional brushed motors.

Who Uses Plunge Routers?

Plunge routers are relied upon daily by a wide range of tradespeople and woodworking enthusiasts, including:

• Joiners and Carpenters: For cutting housing joints, creating mortises, and edge profiling on doors, windows, and staircases
• Kitchen Fitters: Essential for worktop jointing, creating sink cut-outs, and fitting mason mitres with precision
• Cabinet Makers: For cutting grooves for drawer bottoms, creating decorative mouldings, and precise template work
• Shop Fitters: Used for creating displays, signage, and bespoke retail fixtures requiring accurate edge work
• Flooring Specialists: For cutting expansion gaps, trimming door frames, and creating recesses for pipework
• Furniture Makers: Essential for inlay work, creating decorative details, and edge profiling on bespoke pieces
• Property Maintenance Professionals: For repairs, alterations, and general joinery work across domestic and commercial properties
• DIY Enthusiasts: Homeowners tackling kitchen installations, shelving projects, and general woodworking improvements

How to Choose the Right Plunge Router

Collet Size and Power: Start by considering your typical applications. For intricate work, hinge recesses, and general routing tasks, a 1/4" plunge router between 600W and 1200W offers excellent control and manoeuvrability. For heavier-duty work including worktop jointing and large-diameter cutters, opt for a 1/2" model with at least 1800W. Some routers accept interchangeable collets, offering maximum versatility.

Corded vs Cordless: Mains-powered routers deliver consistent power for prolonged use and demanding applications, making them ideal for workshop environments. However, 18V cordless models from Makita, DeWalt, and Bosch offer excellent freedom of movement for site work, particularly when access to power is limited. Consider whether you already own batteries from a particular manufacturer's platform to maximise value.

Variable Speed and Control: Look for models with electronic variable speed control, allowing you to match the RPM to your cutter diameter and material type. Soft-start motors reduce kickback and improve accuracy, whilst constant electronics maintain speed under load. Depth adjustment mechanisms vary significantly – look for clear scales, fine adjustment wheels, and secure locking mechanisms.

Build Quality and Features: Premium brands like Festool and DeWalt's professional range offer superior dust extraction, more precise depth adjustment, and better ergonomics than budget alternatives. Consider whether you need compatibility with guide rail systems, which dramatically improve accuracy for edge work. Transparent bases aid visibility, whilst LED work lights help when working in poorly-lit areas.

Budget Considerations: Entry-level models from Draper and Black & Decker suit occasional DIY use and cost between £50-£100, whilst mid-range machines from Bosch and Einhell (£100-£250) balance performance and value for semi-professional use. Professional-grade routers from Makita, DeWalt, and Festool (£250-£600+) justify their premium through superior durability, precision, and comprehensive warranty support.

Popular Accessories

• Router Cutters and Bits: An extensive range of profiles available with 1/4" or 1/2" shanks, including straight cutters, bearing-guided edge profilers, and decorative moulding cutters. TCT (tungsten carbide tipped) cutters suit general use, whilst solid carbide suits demanding applications.
• Guide Bushes: Essential for template work and pattern following, available in various diameters to suit different applications and maintain specific offset distances from your template.
• Router Tables: Transform your plunge router into a static spindle moulder by mounting it inverted beneath a table, ideal for profiling smaller workpieces safely and accurately.
• Guide Rails and Accessories: Precision aluminium rails with compatible adapters ensure perfectly straight cuts for edge profiling and worktop jointing, particularly useful with Festool, Makita, and DeWalt systems.
• Dust Extraction Adaptors: Connect your router to a workshop vacuum or dust extractor to minimise airborne particles and maintain a clearer view of your cutting line.
• Parallel Fences: Adjustable guide fences that run along the workpiece edge, essential for creating consistent grooves and rebates parallel to edges.
• Router Mats and Pads: Non-slip mats protect workpiece surfaces and reduce noise whilst providing stable support during routing operations.

Safety Information

Plunge routers are powerful machines that demand respect and proper safety precautions. Always wear appropriate PPE including safety glasses or a full face shield to protect against flying chips, hearing protection (routers commonly exceed 90dB), and a suitable dust mask or respirator as routing operations generate significant quantities of fine dust. HSE guidelines recommend adequate dust extraction where practicable, particularly when routing MDF or treated timber.

Never operate a plunge router without ensuring the workpiece is securely clamped or supported. Always check the cutter is properly seated in the collet and tightened with the correct spanners before switching on. Feed the router against the rotation of the cutter (typically left to right on outside edges) to maintain control – feeding in the wrong direction can cause the router to "grab" and pull itself along uncontrollably.

Ensure all depth adjustment locks are secured before commencing work, and never attempt to adjust the cutting depth whilst the motor is running. When changing cutters, always disconnect from the mains supply or remove the battery pack. Allow the cutter to reach full speed before plunging into the workpiece, and never force the tool – let the cutter do the work at an appropriate feed rate.

Keep the work area well-ventilated and maintain electrical safety by using 110V transformers for site work where available, or ensuring RCD protection on 230V supplies. Familiarise yourself with the emergency stop procedures before use, and never operate a router when fatigued or under the influence of medication that may affect concentration.

Frequently Asked Questions

What's the difference between a 1/4" and 1/2" plunge router?

The primary difference is the collet size and consequently the power and size of the machine. 1/4" plunge routers are more compact and lightweight, making them ideal for intricate work, edge profiling, and general routing tasks. They typically range from 600W to 1200W. 1/2" routers are larger, more powerful machines (usually 1800W+) designed for heavy-duty applications like worktop jointing and using large-diameter cutters. Some routers accept both collet sizes through interchangeable collets, offering maximum versatility.

Can I use a plunge router in a router table?

Yes, most plunge routers can be mounted upside-down in a router table, effectively converting them into a static spindle moulder. However, some models are better suited to this than others – look for routers with accessible height adjustment from above the table and convenient power switches. Some manufacturers offer dedicated router table inserts and lift mechanisms for their plunge routers, making table mounting more convenient.

Do I need variable speed control on a plunge router?

Variable speed control is highly beneficial, particularly when using large-diameter cutters which should be run at lower speeds to prevent burning and maintain control. Different materials also benefit from different speeds – hardwoods often route better at higher speeds, whilst plastics and laminates may require slower speeds to prevent melting. Whilst not essential for basic applications, variable speed significantly expands your router's versatility and improves cut quality.

How often should I replace router cutters?

Router cutter lifespan depends on usage frequency, materials being cut, and cutter quality. TCT cutters typically outlast high-speed steel by a significant margin. Signs that cutters need replacing or sharpening include burn marks on the workpiece, excessive effort required to feed the router, rough or torn grain, and visible damage to cutting edges. Professional users may sharpen or replace cutters monthly, whilst occasional DIY users might find quality cutters last several years.

Are cordless plunge routers powerful enough for professional use?

Modern 18V cordless plunge routers from professional manufacturers like DeWalt, Makita, and Festool offer impressive performance that suits most routing applications, particularly with brushless motor technology. Whilst they may not quite match the sustained power of large corded 1/2" routers for continuous heavy-duty work, they excel for site-based joinery, kitchen fitting, and general routing tasks where mobility is valuable. Using high-capacity batteries (5.0Ah or above) ensures adequate runtime for professional applications.