Which router for inlays?

[deepcreek]

Which Festool router would you choose for doing inlays using the Whiteside template kit (unless Festool makes an accessory for this)?

I have an upcoming project with several butterfly inlays and another where I need to inlay about thirty 4x4 tiles into a bunch of 1x6's. 

I'd normally just reach for my PC690 with the plunge base but dust collection is important on this job.

Thanks for your advice!

Joe

p.s.  This will be my first Festool router.  Yeah!

 

[Julian Tracy]

No question - the 1010.  I wouldn't want to be using the 1400 for anything as delicate as that, plus you've got a crappy sight line at the bit with it.

If not the 1010, then either of the two new small plunge routers from either Dewalt or PC.

JT

 

[Jesse Cloud]

Couple of things...
What is the shank size on the whiteside template kit?  The OF1010 takes 8mm and 1/4 inch bits.  The OF1400 takes those plus 3/8 and 1/2 inch.

The big advantage of the of1010, in my opinion, is its small size.  Thats handy for some applications, but with a template app, you want to ensure that the bit stays perpendicular to the workpiece, meaning a generous space for the router to sit on.  OF 1400 is better in that respect.  Additionally, the template guides (not needed with the whiteside kit) on the 1400 are much better than those for the 1010.  Also the racheting collett is brilliant on the 1400 - saves a lot of time and labor.

My advice would be to go to a store that can demo them both (and buy there) to see which has the better feel for you!

 

[John Stevens]

FWIW, I've used the OF1010 with the Whiteside template kit.  Just for two inlays, but it worked well.  I bought an adapter from Leigh (the router jig folks) so the Whiteside bushing would fit.  Hope this helps.

Regards,

John

 

[mouppe]

OK, I am going to buck the consensus here. I use my OF1400 and here is why.

First, I use a marking knife to score the wood at the edge of the inlay. Then I use the OF 1400 to get close to the lines. I like it because it has a wide base- in fact I use the table widener base if possible- it is heavier and more stable than the 1010. I do not use dust extraction with it because I want to be able to see the bit clearly, but I manually pass the vac hose every 10 seconds or so. Routing such a small area (only 1/8" deep) produces very little dust anyway.

I clear the remaining waste with chisels.

 

[PaulMarcel]

+1 to what Richard said.  Small inlay doesn't imply a small router.  I don't have an OF-1010 to speak of it specifically, bu the weight of the OF-1400 or (ghads!) OF-2200 would be a plus.  The bit and wood couldn't conspire to move the router; you move it.  Also the dust from the outline of an inlay like that is pretty trivial; if anything, makes you appreciate the collection abilities of the router

 

[deepcreek]

If not the 1010, then either of the two new small plunge routers from either Dewalt or PC.

I've been seriously tempted by the little Dewalt trim router with the plunge base but I'm trying to buy green tools now.

There is a serious deal on the Dewalt two base kit at Amazon through today with $20 off plus a $30 mail in rebate.

As for the Festool, I still can't decide between the 1010 and the 1400.

 

[deepcreek]

Okay, I caved in to the deal for the little Dewalt trim router with the plunge base.  And then, I bought a Festool OF 1400 to go along with it.

I'm not going to like my Amex bill next month but I sure am going to enjoy my new routers!

 

[Wood_Junkie]

I am going to be the fringe answer here... but the OF2200 seems like an inlay dream.

Yes, a huge, heavy router, high priced for the task.  In fact, I do not own one.  But when I attended the advanced router class, I was struck by several characteristics of the OF2200:
  1) It has extremely good visibility of the cutting area.
  2) It has a clear, enclosed shrouding of the cutting area.  So you get excellent DC, and still have excellent visibility
  3) The weight of it means it doesn't move itself around doing small cutting tasks.  I felt you could freehand rout delicate inlays with the OF2200 because it's so hefty it won't bounce itself around.
  4) Despite its weight, it isn't hard to manuever in small amounts (i.e it slides nicely)
  5) Micro adjustable plunge depth and rock solid locking.  Need that inlay 0.1mm deeper?  Yes, you can adjust it that finely, if not more.

Anyway, I don't do anywhere enough inlay to warrant the $800 Beast of Wendlingen.  But as mentioned, when I used the 2200 my first thoughts went to these tasks.

 

[GaryLaroff]

Here are a few alternate approaches.

I don’t have any Festool routers as no one on eBay wants to sell them at half of list price.  For visibility and maneuverability reasons, I wouldn't use my Elu plunge router or PC routers for shallow or deep inlays.

For highly detailed shallow inlays of depth up to around 3/32 inch (2.5mm) I use a Dremel 4000 running at around 30,000 rpm with end mills down to a diameter about 1/64 inch (0.4mm).  For a router base I use the Stewart MacDonald Precision Router Set:

http://www.stewmac.com/shop/Bindings,_trim/Tools_for_Binding/Precision_Router_Bases/Precision_Router_Set.html

The router base is very good and the auxiliary air pump keeps the field of view open.

For larger and deeper inlay mortises I’ve chosen to go with a Bosch laminate trimmer with the Micro Fence plunge base which they call the Three Axis Mill.  The project this evening has been to rout out mortises in the front of a set of drawers to inset drawer pulls.  The oval mortise is around 3 inches wide and 7/16 inch (11 mm) deep.  The setup is done the same way Richard does it by tracing the shape needed and then cutting in the outline with a marking knife.  Then I use the laminate trimmer/router base with a 1/4 inch bit.

The plunge router base is wide and forms a stable base for detailed mortising.  It has a large clear plastic sub-base and an LED light that illuminates the field of vision.  The router base accommodates four lights and I plan to add a second one even though I haven’t needed it.

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This is a close-up of the 1/4 inch spiral router bit, clear sub-base and well lit field of vision.  All controls on the router base are smooth and superb.

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This is the mortise that was cut:

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This is the drawer pull pushed partly into the mortise to check the fit.

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Gary

 

[Ken Nagrod]

Gary,

You obviously like that Micro Fence router base.  Anything you don't like about it or you feel needs some improving?

 

[GaryLaroff]

Ken,

Nothing yet that bothers me.  I expect the sub-base will get scratched up so I should buy a spare to have on hand.  The engineering on the Micro Fence router base is superb and perhaps even over-done.  One hex tool is used for the non-finger adjustments and the router goes in and out of the base in seconds.  The plunge is super-smooth.  I haven't used the micro depth adjustment yet but will need it and the micro adjust on the fence by the end of July and will repoprt back then.

Gary