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Introduction

The Pieces

The DW618PK is a router kit, a popular offering of the major manufacturers. The DW618PK kit includes the following:

• Aluminum motor body containing a 2-1/4 HP electronic variable speed motor (8,000 - 24,000 RPM) with soft-start circuitry. The motor housing includes a spindle lock. The shaft is machined with a through hole for the spindle lock and two wrench flats--giving the user the choice of tightening/loosening bits using the spindle lock and a single wrench, or two wrenchs. The motor is very compact for its HP output--though weight is what you would expect (it is not particularly light).
  
  
• Aluminum fixed base (DW6184) with a LEXAN (clear) sub-base, tool-free cam lock, quick release motor latches, and overmolded rubber handles.
  
  
• Aluminum plunge base (DW6182) with a LEXAN (clear) sub-base and overmolded rubber handles. The base includes in-built dust-collection capability and an adapter that cleverily accepts two hose diameters. The larger diameter (1-1/2") fits our Fein hoses, the smaller diameter (1") accepts our Festool hoses.
  
  
• Two collets (1/4" and 1/2") and one wrench.
  
  
• Sub-base centering cone used to center sub-bases to the router spindle.
  
  
• An extra LEXAN (clear) sub-base with a 2-3/8" clearance hole.
  
  
• Detachable cord that mates with motor housing and the optional D-Handle base.
  
  
• A large, molded plastic box that holds the above components.

In addition, we had the opportunity to use the DW6183 aluminum D-Handle base. This base is included in the DW618B3 three base kit, or it can be ordered separately. Like the fixed base, it has a rubber molded handle, tool-free cam lock, and the quick release motor latches. The D-Handle base includes a shorty cord that connects to the motor housing--the kit's detachable cord mates to the bottom-rear of the D-Handle base.

What I Like About the DeWALT 618 Router Kit

Depth Adjustments -- No-Tool Base Interchangeability
Precise and consistent depth adjustments are made possible by the DW618's unique depth adjustment design whether you are using the rounter in hand, or mounted upside down in a router table. The DW618 fixed and D-Handle bases employ a set of two, spring-loaded, quick release latches that prevent the motor from wobbling, moving or dropping, even slightly, after you open the base's locking lever.

To adjust bit depth, open the locking lever and turn the large depth adjustment ring clockwise to raise the cutter or counter-clockwise to lower the cutter. To remove the motor body from the base, open the locking lever, depress (and hold) the two spring-loaded quick release latches, and pull the motor out of the base. Since the motor body does not rotate as you adjust its depth (or remove it from or insert it into the base), the position/orientation of the cord, on/off switch, and speed control does not change in relation to the operator/handles. Perhaps more importantly, when adjusting depth, the cutter remains in the same position relative to a fence or jig you might be using. This is important when routing mortises (no stepped mortises) and dovetails.

For what it's worth....I prefer the DW618 depth adjustment method to the method employed by our Bosch 1617. The 1617 includes both a "coarse" and "fine" depth adjustment. The coarse adjustment is a matter of sliding the router to one of two positions in the base. Once in one of the two coarse positions, the fine adjustment knob moves the motor body in microfine increments. It seems like the depth I want to reach, is always out of reach of the find adjustment knob! The Bosch system is more clever than practical in my experience.

Depth Adjustment

Finally, you can move the motor body between the three DW618 series bases without using a single tool, as demonstrated in the following video.

Changing Bases

Power and Wide RPM Range
The DW618 produces excellent power (2-1/4 HP) for a moderately small router. The motor has never bogged in any of our operations. The soft-start circuit prevents any jerk in the router when you start up--in fact, at times, the soft-start, delayed ramp up was almost annoying. The variable speed provides a wide range (8,000 to 24,000 rpm) of speeds that allows the operator to tune the speed to the work piece material and the type / size of cutter.

Clear LEXAN Sub-Bases
The clear LEXAN sub-bases provide an additional level of vision compared to their opaque counterparts. I am a strong advocate of Pat Warner's sub-bases for the same reason. Though useful for any operation, the clear sub-bases are especially valuable when using the router with jigs (i.e., dovetail jigs).

The sub-bases are flat and accept Porter Cable-style guide bushings (except the extra, provided sub-base with the large diameter clearance hole). The bases are secured using pan-head screws. This allows a small amount of adjustment to center the sub-base to the router spindle. Manufacturers typically use flat head screws to mount router sub-bases that self-center themselves in their holes and countersinks, and thus do not allow you to nudge them for centering adjustments.

D-Handle Sub-Base
The D-Handle base stole the show. D-Handle bases definitely add another level of control compared to their conventional fixed-base counterparts. First of all the large D-Handle provides comfortable and firm control of the router--providing enough "leverage" that you can almost use the router one-handed. Second, the handle provides a trigger-style on/off switch (and switch lock) that allows you to turn the router on/off without removing a hand from a handle, required by conventional fixed-base routers.

The D-Handle base provides two positions for the leading rubber molded handle--thus, both right and left handers should have no trouble finding a comfortable position for their leading hand. Even though I like the balance and comfortable handles of the DeWALT fixed-base, I tend to use the D-Handle base more because of the added control and its convenient trigger-style on/off switch.

Since the motor body uses a detachable power cord, the D-Handle base includes a shorty cord. Simply connect the cord of the D-Handle base into the motor body and connect the detachable cord into the rear of the D-Handle. Works great.

Spindle lock or Two Fisted Wrenches -- Your Choice
We own several routers with spindle locks and frankly I do not care for them. The Festool OF1000 spindle lock was the first spindle lock I used without filling the air with colorful language.

The DW618 motor uses a spindle lock similar to the Festool--a hole is machined completely through the router spindle that mates with a spring-loaded pin. In my opinion, this style of spindle lock provides a more secure and easier to use lock than those that slide a piece of sheet metal past two flats. For those who prefer the two-fisted wrench method of loosening and tightening collets, the DW618 spindle is machined with flats that matches one end of the included wrench--only problem is you'll have to scare up or purchase a second wrench.

Bit changes are further simplified by a flat-top motor housing and generous openings in the bases. And for those who prefer removing the motor from the base to change bits, all three bases provide tool-free, locking levers (and the quick release latches on the fixed bases).

Detachable Cord
Again DeWALT has taken something from the European design. Detachable cords make sense for a number of reasons, for instance, they're easy to replace and you can use one cord for multiple tools. It's really not a big deal but, thanks to Festool, I have come to like the concept of detachable cords. Now if only the manufacturers would decide on a standard connector!

Dust Collection
I like the idea that the plunge base provides dust collection using DeWALT's through-the-column path. This vertical connection, though perhaps less efficient than those that take a straight shot out the side/back of the base, places the dust collection hose out of the path of the router and interferes less with the operator's control of the router. I found that the dust collection worked satisfactorily when the entire base covered the work piece performing mortise and dado operations. However, the dust collection seemed almost nil when performing edge operations. The plunge base includes an easily removable clear plastic shroud that helps funnel debris into the dust collection port and prevents debris from being ejected up at the operator. Very clever and functional.

The included vacuum hose adapter worked well with the large diameter hoses we use with our Fein and Festool dust extractors. The adapter cleverly provides two diameters that covered the two diameters of our shop vacuum hoses (Fein and Festool). But I found in practice that the Festool hose would not stay fixed to the inner, smaller diameter fitting. Click the picture to the right to view a closeup of the vacuum hose adapter.

Unfortunately, the DW 618 fixed and the D-Handle bases do not provide dust collection capability. Consequently, if you're anxious about dust collection, you might want to consider retrofitting these bases with the Leigh RVA1 Router Vacuum Attachment (approximately $45). In defense of DeWALT, most fixed bases do not provide dust collection, the new Porter Cable 800 series vac-handle base being the exception.

Pat Warner
The DW618 must be good, Pat Warner (renown router guru) gave it high marks! Click here to read his review. Pat Warner also offers his quality aftermarket bases for the DW618 (as well as the DW625 and DW621). I use his sub-bases and highly recommend them.

What I Don't Like About DeWALT 618PK Router Kit

Edge Guide Not Included With Kit
I was surprised that the kit did not include an edge guide/fence. Furthermore, screws/knobs are not supplied with the bases to attach a shop-made edge guide. Our Bosch kit came with a decent edge guide--I assumed the DeWALT kit would as well.

No Fine Height Adjuster
The plunge base does not include a fine height adjuster, nor have I seen one offered as an option. In all fairness, Bosch does not supply a fine height adjuster with their competing router kit.

Kit Box
The plastic kit box is huge, but does not provide space for all three bases. Even though the interior of the box is molded to fit the bases and has pockets and holes to accept accessories and router bits, everything seems to end up rolling around inside as soon as the unit is closed up and transported. If DeWALT allows us to purchase our demo unit, we will discard the kit box, or perhaps fix it to a concrete foundation and use it as our long-awaited finishing room.

Plunge Base Does not Compete With Dedicated Plunge Routers
Though better than nothing, the plunge base does not compete feature-for-feature with dedicated DeWALT or competitor plunge routers. The plunge action, like our similar Bosch plunge base, is a bit springy and just does not have the solid integrated unit feel of high-end plunge routers. It does not employ a trigger on/off switch in the handle. The depth adjustment stop and rule are a bit primitive compared to other DeWALT plunge routers. With that said, it does plunge, it includes dust collection, and I prefer it to our Porter Cabler 693 and Bosch 1617 kit plunge bases.

A Few More Comments....

Router Kit Plunge Bases
Generally I am not impressed by the plunge bases Porter Cable (PC 693) and Bosch (RA1166) include in their respective kits. They are bare bones plunge bases. The DeWALT plunge base is not much different, but does include a few features worth remarking:

• Includes the before-mentioned dust collection.
  
• A slightly better-than-average depth-stop arrangement. Though the base does not include a fine adjuster nor a hairline cursor common to dedicated plunge routers, the DW618 plunge base includes a knurled headed screw at end of the depth stop rod that you can use to fine-tune the stop. It employs a light spring to prevent it from loosening.
  
  
• A bronze bushing is employed between the base and the large column, another quality touch. There is absolutely no stiction or flex when plunging.
  
  
• If you play with the Plunge base at the store without the motor (as I did), you may misjudge the plunge action to be too springy. However, the motor body loads the springs just enough to result in a nice feel--not the dampened feel of the Festool OF1000, but a good feel nonetheless.
  
  
• Very comfortable handles.
  
  
• Most plunge routers cannot be turned onto their tops to remove/replace cutters. The DW618 has a flat top and has nothing protruding beyond its flat top. Consequently, with its excellent spindle lock, removing cutters is a bit easier than our other plunge routers (Festool OF1000 not included).
  
  
• The clear LEXAN base and large open area between the columns provide a great view of the cutter and work piece.

The Bottom Line

The DW618 is the best fixed-base router I have used for general routing. The unit is compact and even though it is not particularly light, it is balanced very well without the slightly top heavy feel of the Bosch 1617. The fixed-base height adjustment is simple, precise, and easy to use. The clear LEXAN sub-base is easily centered to the router spindle and provides an excellent view of the cutter and guide bushing as they work their way through the fingers of dovetail jigs. Swapping bases is simple and quick, requiring no tools. The DeWALT's attention to detail and perhaps attention to a few design features of routers from the other side of the Atlantic is very apparent (I have a feeling the DW618/DW625 are designed/manufactured in Italy)--the DW618 has all the modern features: power, soft-start/variable speed electronics, and balance I look for in a router. The D-Handle and plunge bases are icing on the cake. In case you're wondering, we purchased this unit directly from DeWALT.

Rating:

out of 5!

More Pictures

Click here to view additional pictures of the DeWALT DW618PK from DeWALT.

Comments From Readers

Jim Becker has also reviewed the DeWALT 618PK Router kit. Click here to read his review!

Tim Hughbanks wrote the following:

Jack,
That was a very comprehensive review of an excellent tool! I just purchased the DW618B3 kit a couple of weeks ago at the KC show and couldn't be more pleased with it. As a show incentive, the kit also included the edge guide as well as a DW411 sander. Great bargain! The kit, which also includes the D-Handle base, has a case that houses all three units as well as a space for the edge guide. I will be using this solely for hand held use as I have a 3-1/4 HP Freud dedicated to my router table. But, having said that, I have few doubts that it would be more than capable of handling most projects on the table as well. I do love my Freud though :). Anyway, count me in as another very satisfied user of this tool.

Art Johnson wrote the following:

Hi Jack,
I bought the DW618 when they first came out over a year ago and am delighted with it. Your review is right on (naturally) and I agree with both your pro and con issues. I had the DW625 under my table which I really enjoyed but wanted another router for hand operations.

Naturally, I was going to get the popular DW621 until Dewalt came out with the DW618PK so I choose it. Just to try out the fixed base, I removed my DW625 from my router table and replaced it with the DW618 fixed base. As a tribute to the DW618's performance, the fixed base is still installed under my table and I have never had a hint of it bogging down. It is just so easy to remove the motor from the table and install it in the plunge base that it isn't worth the bother to unpack the DW625. Now I confess I did replace it once to do a series of raised panel doors but that was not because the DW618 couldn't handle the job, I have done many raised panels with the DW618. I just wanted to save some wear and tear when doing what amounts to a production run of the panels. As noted in your review, changing bits is a snap. Drop the motor, sit it on it's top and bit changes take seconds.

Bottom line:

If I was considering my first router or wanted a flexible router for hand operations that could also back up my table router, the DW618 is difficult to beat. At least, worth a serious peek.

Great review as usual, Jack.

Art

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