Assembling Triton router puzzle

A couple of years ago I dismantled and reassembled my router using Ray's excellent instructions - no problem.

Yesterday I decided to use the depth stop for the first time, it's not something I normally bother with. Was puzzled to find that the depth stop tube wouldn't fit over the depth stop bolt because the end was plugged about 5mm up the tube.

Thought that I must have put the depth stop tube in the wrong way round so dismantled the router again. But no way it works that way round either because the plastic spring location peg doesn't reach into the hole in the housing so the spring just buckles into the gap. In any case it conflicts with Ray's instructions "Ensure the depth stop is released to its fullest extent" because if its that way round it comes out altogether.

I can't see any parts that I'm missing on the parts list. I'm probably missing the obvious (happens a lot) but please can somebody help me out.

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Originally Posted by Glennet

Yesterday I decided to use the depth stop for the first time, it's not something I normally bother with. Was puzzled to find that the depth stop tube wouldn't fit over the depth stop bolt because the end was plugged about 5mm up the tube.

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That's weird, Glen. The business end of the depth stop tube should be hollow for at least 30mm, otherwise it wouldn't fit over the posts in the picture below:
http://www.raygirling.co.uk/images/triton10.jpg

Is it bunged up with compacted dust, or can you see another physical obstruction?

Ray

Hi Ray

Thanks for replying and the photo.

It looks like the end has a metal plug about 5mm up the tube. It looks like something factory fitted and feels like metal. It is solid. I can't push it up the tube, rock it or scrape material off.

How is it supposed to be? I imagine a tube with a deep hole for the spring on the slightly belled end and a shallower hole on the plain end to fit over the post.

The parts list shows a 'plug'. I wonder if mine could have somehow got displaced?

Options are to belt it hard to try and move it up the tube or drill it out or live with it. Before I do something destructive I want to be sure I'm not missing the obvious though.

Where about in Melbourne are you?

I could drop one of my complete routers around to compare to see how yours is different to diagnosed the prob if you're not to far out of my travels and if yours is somehow wrong, could possibly spare one for you depending on model or if they're interchangeable between the 2 models.

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Originally Posted by Glennet

Options are to belt it hard to try and move it up the tube or drill it out or live with it. Before I do something destructive I want to be sure I'm not missing the obvious though.

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OK, I've now taken mine apart and had a look at the depth stop tube. As you say, the flared end remains inside the housing and the spring fits inside it. The stop certainly appears to be metal, positioned within the tube so that it provide a stop for both the spring and the adjustable thread(s) on the turret.

I then measured everything carefully for you. Please note the following dimensions:

Length of whole tube = 118mm
Depth of spring cavity = 78mm (flared end to internal stop)
Depth of plunge cavity = 30mm (plain end to internal stop)

Therefore, the metal stop must be 10mm in length and it seems that yours is badly positioned within the tube. It would appear to be an interference fit, but it must be a very tight fit, otherwise the spring pressure would move it, rendering any pre-determined plunge stop setting useless.

After I had reassembled my router, I took a look in my spares box, only to find I have a spare tube and spring! What I'd suggest you do is to try to tap the plug upwards with a suitable drift until it's 30mm from the plain end, knowing that I'll quite happily put my spare tube and spring in the mail for you if it goes pear-shaped. HTH :)

Ray

Thanks for the two generous offers - that's awesome.

You are right Ray, the plug was wrongly positioned. I tapped it back to your dimensions then cross-drilled the tube and put a rivet through to make sure. Everything reassembled and its working fine.

Thanks again for going to so much trouble to help out.







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Originally Posted by Glennet

I tapped it back to your dimensions then cross-drilled the tube and put a rivet through to make sure.

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Can you still plunge it fully (for bit-changing) with a rivet in the tube? :oo:

Ray

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Originally Posted by rayintheuk

Can you still plunge it fully (for bit-changing) with a rivet in the tube? :oo:

Ray

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I countersunk it both sides and filed and emery papered the heads totally flush with the tube wall. You can hardly see its there without a magnifying glass.

I should have known - well done! :)

Ray