You know, I don't know what I would do if I had an eleven year old tool tha t needed repair. I would think I would be figuring out how many road miles it had on it before I would repair it. Eleven years in _your_ shop seems like a really long run. But if I liked the tool and its results, I could b e pretty forgiving, in this case if the bearings and brushes were still goo d.
Many years ago I needed to cut some door panels and make a bunch of trim fo r a really neat custom job I landed. I looked at a lot of routers and at t hat time the big Porter Cable was still around. But the build quality had fallen so much those that had the newer ones steered me away. I seem to re member screeching bearings for some reason, although that may be wrong.
So that left Hitachi, Milwaukee and DeWalt. Don't remember why I passed th e Hitachi. Didn't like the fit/finish of the Milwaukee, nor the fact that the soft start wasn't very soft at all. IIRC, it is now made in China and w ith a few manufacturing changes is a good router.
I HATE those damn handles, and under a table they take up a lot of room. A lso, upside down, this machine is a nightmare to adjust. To me, this tool was made to be a lightweight shaper that never left the table. Also, from time to time I still use 1/4" shank bits, and a 1/4" collet does not come w ith this machine. It is another $40-$50.
So down to the DeWalt. Not always crazy about their tools, and haven't alw ays had great luck with them lasting. However, when I got this machine hom e, it was love when I switched it on. Really nice soft start, not nearly a s loud as the Milwaukee or the Porter Cable. This one came with the 1/4" c ollet in the box.
It has plenty of power, doesn't require a suitcase sized table (this is ver y similar in size to the Triton) and is extremely well made. It is made in Italy by Elu from Italian and Swiss parts. The electronic speed control h as been flawless. Under the table it is a breeze to adjust since I bought one of these
for it. Some of the guys online that showed me their setups made nice adju sters with a piece of pipe, a coupler nut and turned a nice looking wood kn ob for the same purpose. When I found that for $15 at the time I purchased it, it was a no brainer.
I don't know your setup for raising panels, but I am honestly afraid of the horizontally spinning router bits that should be in a shaper. There was a guy here locally that was using CMT bits to raise his panels and the bit b roke and nicked him and half of the head lodged in the garage wall. At the time I was also on Sawmill Creek, and although quite rare, a couple of fel lows had the same result. Even figuring in that at least one wasn't using the setup correctly, I am thinking about a bit going in a machine that in u se just doesn't look safe to me.
I put the panels on edge and cut away as much as possible on a table saw. Then I use a vertical panel raising bit to make my cuts. The vertical bits cut a bit slower than the horizontally mounted since you don't have the mo mentum behind that develops behind that large horizontal head, but the fini sh is fine. I never have made a lot of doors and now rarely do. The route r has plenty of power for dadoes, edging, and making passes with odd bits t o make some "one off" shop designed trims. It can profile cut ton of trim without overheating, and creates enough air flow around it even in the clos ed box I made that it doesn't overheat. This router has been a really solid performer and a joy for me to use. It has left the table from time to tim e to edge or trim something as needed and it is easy to hold, aim and use.
The only knock I have heard (but not found to be a problem for me) is that it doesn't plunge as deeply as some of the other routers in its class. I g ot rid of the base that came on it and made a really large phenolic base, a nd even after losing the thickness of the base, I still have no problems. If I did, I would probably buy a bit extender and be done with it, but at t his point no problems. I think this is one DeWalt got right.
Robert