At present I have a Porter Cable 2 HP router that will plunge about
Vic
This should get it done. I heard a few bad reports when these came out, but later on it turned out to be operator error. For what you want (not worrying about lateral loading so much) they should be fine:
Robert
Milwaukee 2 1/4 hp 2 7/8" plunge Porter Cable 3 1/4hp = 3" plunge Etc. Get a up-cut spiral bit and you are good to go. I would still do it in a few steps maybe 1/2" to 3/4" per pass depending on the material. Just make a good jig so you can good repeatable passes.
Maybe like this (one of my fav's)
The router collet extension sold by MLCS mentioned above looks good. BUT t he wrench flats on the extension piece are about 1 inch or so around. If y ou were trying to extend a 1/2" spiral bit that is 4" long for example, the wrench flats would prevent you from using the extra length the extension p iece provides. It kind of only works as an extension if you are routing a hole that is 1-1.25-1.5 inches diameter or greater. So the wrench flats ca n fit into the hole you routed. Not sure this extension piece is really ve ry useful in the real world. Most holes I rout are 1/2" or less. Rarely r out holes over 1 inch in diameter.
I have the Porter Cable 7539 router mentioned above. Great router. 3" plu nge. 5 speeds. Soft start. 1/2" and 1/4" collets available.
Since the 7539 is designed for heavier work, it appears to be the safest option if you're determined to acquire that extra plunge depth. In principle, extensions can address the reach problem, but in practice, as Russell pointed out, they quickly become difficult. For deep mortises, a router with a true 3" plunge will be more dependable and save you a great deal of trouble.
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