I bought a 2 1/4 HP Bosch D-Handle router for that very purpose (cutting sheathing in window and door openings). We use a 1/2″ single flute pilot panel bit and it hogs through 1/2″ CDX like butter. It’s fast and clean and makes for a great looking frame. Watch out for nails and hardware or you’ll be losing big coin replacing the bits.
We weren’t really sure of it’s limits at first though. Burnt up the internal speed control switch (or something like that) trimming up 3/4″ Advantech subfloor with a dull bit. All that glue and resin is just too much work for it. Bosch repaired it for free under warranty….. twice. I’m a slow learner.
That router gets tossed around like a circular saw and takes an awful lot of abuse. I’m very happy with it. In fact I just made about 150′ of cedar deck railings with it a couple weeks ago and it still worked beautifully for the detail work as well.
I’ve also got a Milwaukee 1 3/4 HP body grip router that I bought while the Bosch was getting repaired. That’s a nice router too, but I highly recommend going with a 2 1/4 HP for this kind of rough work. The D-handle on the Bosch is also much better suited than the body-grip.
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That kind of routing will put alot of stress on the router. I think you should go with a 3 1/2 HP Porter Cable. I use one on a table and it runs through everthing - no problem.
What does this situation in my life ask of me?