So, long story short, I bought a jig for making a very specific thing. This setup comes with a specialty router bit. It's designed to screw directly onto the chuck. The shank of the bit is oversized, for reasons, and the end is threaded like the collar of a collet.
Now of course not all routers have the same size chuck. So they sell four different sized bits. I have an older router, a Porter Cable 890, and I knew the chuck was on the large side. So I got the largest bit they make. And it's not big enough. And no, they don't make a bigger one.
The bit threads onto a M20 x 1 chuck. Near as I can tell my chuck is M25 X 1.5. So, weighing my options on how to make this work.
1. Adapter? I've found some adapters that would get the job done, if only the bit was M20 X 1.5. But not only do I have to reduce the size, the thread pitch is different. Have not found a solution for that in my googling.
2. Forget the custom bit, buy a similar 1/2 inch end mill bit and use that instead. Might work, but the router plate this system comes with has a bearing in the middle, sized for their bit, which is more like 3/4 inch shank. In order to make very very sure it's absolutely straight. Which is important. So that approach opens up the possibility of some less than ideal cuts.
3. Replace the chuck? I can find replacements of course, but I need to get one of a different size. Which would also render my existing collets useless. Not even sure if that's possible. Can't find info on the thread size/pitch for the shaft the chuck attaches to, not sure if those are pretty standard or if that will be another hurdle.
4. Buy a new router. Not really loving this idea, but it would let me leave my Porter Cable attached to it's router table permanently, then I could use the new one for any handheld work. In this case I'd just buy one of the models suggested for use with the size bit that I have.
5. ???? Something I haven't thought of. Looking for a miracle here, lol.
Now of course not all routers have the same size chuck. So they sell four different sized bits. I have an older router, a Porter Cable 890, and I knew the chuck was on the large side. So I got the largest bit they make. And it's not big enough. And no, they don't make a bigger one.
The bit threads onto a M20 x 1 chuck. Near as I can tell my chuck is M25 X 1.5. So, weighing my options on how to make this work.
1. Adapter? I've found some adapters that would get the job done, if only the bit was M20 X 1.5. But not only do I have to reduce the size, the thread pitch is different. Have not found a solution for that in my googling.
2. Forget the custom bit, buy a similar 1/2 inch end mill bit and use that instead. Might work, but the router plate this system comes with has a bearing in the middle, sized for their bit, which is more like 3/4 inch shank. In order to make very very sure it's absolutely straight. Which is important. So that approach opens up the possibility of some less than ideal cuts.
3. Replace the chuck? I can find replacements of course, but I need to get one of a different size. Which would also render my existing collets useless. Not even sure if that's possible. Can't find info on the thread size/pitch for the shaft the chuck attaches to, not sure if those are pretty standard or if that will be another hurdle.
4. Buy a new router. Not really loving this idea, but it would let me leave my Porter Cable attached to it's router table permanently, then I could use the new one for any handheld work. In this case I'd just buy one of the models suggested for use with the size bit that I have.
5. ???? Something I haven't thought of. Looking for a miracle here, lol.
