soss hinge PC plunge router

I tried to use my Porter Cable 89* plunge router to make soss hinge mortices today, with very dissapointing results. I have alot of WWing experience (25+ years), but I do not have much experience with plunge routers. These results were totally unacceptable. Too much slop in the plunge base. These hinges are 1/2" X 2 3/8". I was using a 1/2" bit with a 3/4" guide in an mdf template. I ended up using the fixed base with the same template, plunging it farmer style. The 24 mortices came out perfect. I guess theres a reason the plunge base has been in a drawer the 2 years Ive owned this tool. The horrid thing wont see daylight again for a long time in my shop.
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snipped-for-privacy@austin.rr.com wrote:

It would have worked better with a 3/8" bit.
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dadiOH
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My initial setup was a 3/8"bit with a 5/8" guide in a template made using a 3/4" forstner bit, but the slop in the porter cable's plunge base produced crappy mortices, That is, an intended 1/2" mortice would actually end up at about 17/32" wide and slightly uneven, which in this project is unacceptable. The final setup I used the 1/2" bit so I would not need the radius on my template. This enabled me to glue up the template using several mdf blocks accurately cut to index both of the mortices the required distance from the top and bottom of doors and stiles. I started the thread hoping to get feedback on the overall accuracy of the Porter Cable 89* plunge base compared to other models. I wonder if this application is just too much to expect from any plunge based router.
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snipped-for-privacy@austin.rr.com wrote:

I use two plunge routers...a Bosch 1611 1/2" and a Porter Cable base for 890 routers used with an old Black & Decker/Dewalt 1/4" router motor. I cut all manner of things with both and have not had any problem with deflection.
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dadiOH
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routers used with an old >Black & Decker/Dewalt 1/4" router motor. I cut all >manner of things with both and have not had any

One thing that PC seems to make that is a good qualtiy product is their line of routers. Seems like they have to recall them a lot (including the 890) but in the end they get them right.
I would think that your setup is out of whack someway. I use an old Porter Cable plunger that I have had for years to mortise door hinges all the time as part of my business. I also have a DeWalt (Elu) 625 plunger that is a as sturdy as a rock. Your 890 is a nice router, well made and sturdy.
If you were able to cut the mortises with our other setup in a satisfatory manner it would seem you have your technique down solid, so it would seem to leave the router. Is there anything in the collet? Are the slides moving freely? Is the plunge base attached properly?
Robert
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wrote:

890 routers used with an old >Black & Decker/Dewalt 1/4" router motor. I cut all >manner of things with both and have not had any

Everything is fine except the secondary bore on the plunge base there is slop. It appears to have a plastic bushing. The primary bore is bushed with bronze and is alot tighter. Ive worked in wood shops most of my life, and never gave much thought to plunge routers. The few times I have used them, I just kind of took them for granted, picked them up and went to work, and never experienced a problem. Usually though, it was an operation where this degree of accurqacy was not required, such as butt hinges in a household door.
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