Failed router template cutter.

[Wychall]

I've just started to use a new Silverline router template cutter and had a catastrophic failure. As soon as the workpiece touched the cutter, the cutter shaft bent which caused it to throw out from the machine. A full face shield saved my beautiful features but I think I might need a seamstress to look at my finger. I believe it to be a faulty cutter so be aware if you use Silverline cutters.

 

[porker]

Hi - The first thing that comes to mind is how far was the cutter engaged in the collet? The bend is quite high indicating that the bit wasn't inserted far enough and there would be a lot of overhang.

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[marcros]

how much was inserted into the router- it seems to have bent very high up on the shaft?

i hope that the finger isnt as bad as it first looks to you.

 

[Steve Maskery]

I believe it to be a faulty cutter so be aware if you use Silverline cutters.

I'm sorry but I think you are mistaken. The cutter obviously was not in far enough when it bent, it could not have bent there if it had been.

If you had put it in far enough and that still happened, I suggest that you had not tightened the collet enough. The cutter came loose and bent on its way out.

I think it must have been one or the other. I've done the same thing myself before now.

I know this is not what you want to hear and I hope that your finger is OK.

Look on the bright side, at least it was not an expensive cutter!

 

[ColeyS1]

Quite often cutters will have a line on the shaft showing the minimum amount it should be inserted in the collet

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[Wychall]

I agree that there may have been insufficient insertion but I am still surprised that the shaft was so soft. I'll await a reply from Silverline with bated breath

 

[iNewbie]

I'm sorry but I think you are mistaken. The cutter obviously was not in far enough when it bent, it could not have bent there if it had been.

If you had put it in far enough and that still happened, I suggest that you had not tightened the collet enough. The cutter came loose and bent on its way out.

I think it must have been one or the other. I've done the same thing myself before now.

There's another possible reason it may have come loose - as we don't know how old his machine is: the nut was tight but the collet is old & cream-crackered.

 

[Mr T]

I would suggest that the shank should be inserted at least three quarters of the way into the collet. But I would also say that buying cheap cutters is a false economy.

Chris

 

[lurker]

I agree that there may have been insufficient insertion but I am still surprised that the shaft was so soft. I'll await a reply from Silverline with bated breath

I agree with the others, user error by the looks of things.
IF the shaft was soft it possibily saved you from a more serious injury: if it had shattered and broke up at speed things could have been far worse.

 

[Wychall]

There's another possible reason it may have come loose - as we don't know how old his machine is: the nut was tight but the collet is old & cream-crackered.

You're getting close. The machine is old (and cheap) but has seen little use. I have dismantled the collet and found it to be chock full of encrusted rubbish which prevented full insertion (oo err!). I understand the comments about buying cheap but if I didn't buy cheap I wouldn't buy at all. We all have to start somewhere.

 

[Eric The Viking]

The accident may well have damaged the collet. Depending on the design of the collet, it might also have been damaged when you tightened it, because the cutter's shaft wasn't inserted far enough: they should stay parallel as the jaws relax, never conical. If it pinches at one end first, that is a sure sign of damage. Also look for damage around the rim, and any hint of asymmetry. I have 1/4" and 1/2" silver steel bars I can drop in the collets, usually to check vertical alignment of the router WRT the router table or fence. They are cheap (less than a decent cutter) and handy for checking, as you can rotate the shaft by hand to check for wobble, amplified by the length of the bar. I got mine from eBay.

Most quality-brand routers have spare collets available, even for quite old models, and there are a number of spares specialists on-line who stock them. Expect to pay £>20 +VAT and carriage (they are precision parts, but I suspect quite profitable for the stockists!). After an accident like that I would replace it as a matter of course, if it's in a small 1/4" router. The one for 1/4" use for my 1/2" model is much stronger, but I'd still check it out carefully.

Also, if the collet was "chock full of encrusted rubbish", the router probably has had a harder life than you imagine. So I'd also check the main bearing (check the shaft rotates nicely, that it isn't noisy when turned by hand, and there isn't any float). If in doubt replace.

You've had a shock, which is probably healthy for power-tool users once in a while (he said, speaking from personal experience). Don't let the thing bite you twice!

If in any doubt...

 

[Racers]

A spokeshave would let you listen to the radio while you worked, you might cut your self while sharpening it, but apart from that its all good.

Pete

 

[sunnybob]

First, yes that bend is too far out, the cutter cant have been in properly. second, its "silverline" Buy something a lot better (that wouldnt be hard to do), and insert the cutter at least two thirds of the way into the collet.

 

[skipdiver]

Silverline stuff is best left on the shelf. There are probably other factors at play here as well which caused the failure, but try and spend a bit more on your router bits if possible. You don't want something poorly made spinning away at a great rate of knots, so close to your precious digits or face. Trend make a decent mixed set for not a lot of money, but even these i wouldn't use for anything more than occasional passes. I do a lot of routing and i like to think that with prolonged use, they are not going to disintegrate before my eyes, so i use Wealden bits exclusively.

 

[marcros]

I have used a few silverline router cutters in the past without issue. I only use them when I need a throwaway or tool station is the only place nearby that is open. They serve a purpose. Generally, the stuff is poor/made to a very low budget, but there are some products that serve their purpose. I have several clamps and they have performed well. People go wild for lidl stuff which is made to the same budget!

 

[skipdiver]

I have nothing against stuff built to a budget and have some Aldi and Lidl gear in my workshop. It's also helpful to people who just do woodwork as a hobby and don't want to invest in expensive stuff, but when it comes to bits spinning at incredible speeds, it's a different proposition.

 

[monkeybiter]

As the OP said, we all have to start somewhere and with too steep a financial entry ramp the hobby may be completely unavailable.
Starting with cheaper tools gives you chance to find out if the hobby's for you and worth greater investment.
As marcros said Silverline stuff 'can' be quite usable, and like others have also said it's most likely just a valuable lesson in 'knowledge preparation' on the never ending learning curve.
You make a mistake, if you're lucky only your pride's hurt, move on better prepared.

 

[skipdiver]

Yeah, good points monkeybiter. We live and learn and hopefully don't sustain any injury along the way.

 

[Cordy]

Hi Wychall

As soon as the workpiece touched the cutter

So your router is fixed in a table ?

Was you moving the wood in the correct direction ? -- right to left ?

 

[Cordy]

template cutter

How much wood was you trying to remove ?

Before using a template cutter it is normal practice to have not more than 5 mm of wood to remove, otherwise your router will throw a tantrum

A jig saw is handy to prepare wood for template cutting if the shape is irregular

Some Silverline products get the thumbs down from me; but not their router cutters, so far they have been OK