Once sure it is working correctly, disassemble the coupler, lubricate the connector bolt and tee nut, and add some Lock-tite to the coupler before reassembling. The connector bolt and attached threaded rod will now compress the motor upward toward the base elevating the bit.



Further notes:

- As this is my first Instructable, let me know if anything is unclear.

- 1/4-20 threading was dictated by the connector bolt, but the thread count is a pain. 1" of travel is 20 turns. 1/4" is 5, and 1/16" is 1 1/4 turns. 5/16-32 would be better, but harder to find tee-nuts.

- As you can see, 8" of threaded rod looks unnecessary, but I'd rather have extra than too little.

- The only visible damage to the router is where I drilled two small holes for the brass nails to prevent the tee nut from turning. The only other hole I drilled is in invisible at the bottom of the threaded socket for the depth stop. I will have no problems reassembling the router with it's original parts. (Provided they don't get reused elsewhere.)





3/8/2008: - One thing I overlooked in the reassembly is the locking mechanism (black lever on the right in below pic). It relies on a small metal disc to press against the post, but falls out easily.

3/13/2008: It seems that the router in the middle of the saw wing is bowing it down a little (1/8"), so I'm rebuilding it by replacing the strips of MDF on the bottom with a full sheet. Add a couple bars of angle or box tubing from HD and it should be much more stable. Router still works like a charm.



Continuation project to come: Dust collection