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The 7 Best Palm Routers to Upgrade Your Woodworking Projects


The 7 Best Palm Routers to Upgrade Your Woodworking Projects

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Using a router gives your woodworking projects the professional-quality, precise look you want. These handheld power tools carve and shape edge profiles and joinery cutouts using a spinning bit, and palm routers -- the smallest type of router out there -- are uniquely suited to more intricate detail work. They maximize grip comfort and control thanks to their compact size, providing users with the maneuverability and accuracy needed for precision work.

While you'll need one of the palm router's more powerful siblings (such as fixed-base and plunge routers) for heavy-duty jobs like panel cutting and large-scale joinery, tasks like trimming, edging, and joinery work all call for the lighter touch of a reliable palm router.

Although palm routers pack less power than other router types, some offer a bit more oomph than others. The more power a router generates, the better suited it is to maintain speed while under heavier loads (such as using larger-diameter bits or working with harder wood like maple). While several factors contribute to the actual power output, consider a corded palm router's horsepower (HP), which ranges from 1 to 1.25 HP, when choosing the best unit for you. With battery-powered routers, look at the stated voltage, which typically ranges from 18V to 24V.

Palm routers use either corded electricity or batteries for their power supply, both of which have their own pros and cons.

These plug into a standard power outlet and operate smoothly and consistently without a limit on their runtime. They're slightly more powerful for the price than cordless versions, but the cord limits your range of motion and the size of your workspace.

With no power cord to plug in or work around, cordless machines maneuver much more conveniently than corded versions. Batteries are limited in runtime, however, so if you work on time-intensive projects, multiple batteries are likely necessary to prevent annoying disruptions.

If you're a beginner with this tool, opt for a heavier palm router, which provides more stability than the lightest models. Also, those working with larger bits or dense wood are likely to prefer a model that comes in greater than 4 pounds. On the other hand, lighter palm routers (3 to 4 pounds) offer more control and maneuverability, which is great for zipping through detail work.

In order to choose the best option for your specific projects, it's important to understand how speed affects the operation and results of your palm router. Revolutions per minute (RPMs) measures the speed at which a router spins its bit and typically ranges from 10,000 to 350,000 RPMs.

While some palm routers operate at a single fixed speed, many feature variable speed controls. Although all palm routers include the recommended RPM relating to bit diameter in their user manual, this chart from Wood magazine is a good start for first-timers.

With their relatively low power output and ¼-inch collet (the collar that secures the bit in place), palm routers typically accept smaller diameter bits than full-size routers. These bits can still offer a ton of routing variety, as long as your router generates the proper speed. The larger the diameter of the bit, the lower the RPMs you need, and vice versa. Because the cutting edge of a larger-diameter bit is actually spinning much faster than that of a smaller diameter bit, this lower RPM prevents excessive vibrations and decreases your risk of losing control of the bit. Alternatively, setting your router speed too low sometimes results in a rougher cutting surface. While shank bits can range from ⅛-inch to 1 ½-inches diameter, the most common bit sizes for palm routers are ¼ inch, ⅜ inch, and ½ inch in diameter.

You should also consider whether you'd benefit from any router accessories, like templates or extra bits, which often come in the form of an included or additional kit. If you're just starting out, a basic router kit with templates and bits lets you get started right away -- no learning curve or extra gear required. If you're an experienced woodworker who already has a bit collection, save some extra cash by buying a standalone router and skipping the kit.

When selecting the options for this article, I first called upon my personal experience working at a custom furniture woodshop in New York City. There, I used a wide range of routers, which gave me the hands-on insight needed to confidently assemble this list of the best. I'm familiar with a range of trustworthy brands, too, and my overwhelmingly positive experience with Bosch routers makes theirs an easy choice as the top pick. I've also used reliable routers made by Makita and DeWalt with success.

For this update, I also utilized the expertise of Roy Behrendshon, long-time editor at Popular Mechanics and tool-testing expert. I used Roy's model recommendations and testing notes to add more router variety and operational insight. As always, we feature a range of prices, so regardless of budget, one of these palm routers will meet your needs.

Bosch power tools retain an excellent reputation for being reliable and straightforward to use, and this variable speed palm router is no exception.

You can easily adjust the speed using the top-mounted variable speed dial -- from 16,000 to 35,000 RPMs -- and precisely customize the bit depth using either inch or metric measurements. Bosch's constant response circuitry also ensures the router speed stays consistent, boosting power to compensate for heavy loads.

An LED light increases accuracy as you work, and the included straight-edge guide securely positions your bit up to 3 ⅝ inches from the edge of your workpiece. The hard-sided carrying case protects your tool and transports conveniently when you're on the go.

Despite the low cost of this Bosch router, it still performs as well as any DIYer could hope for. Its 1-hp motor and variable speed control is useful for a range of tasks, from cutting and laying light-duty laminates to soft-wood rabbeting.

At just over three pounds, this compact tool offers comfortable maneuverability and control -- essential for any routing project. You'll need to use a wrench to swap out bits -- no quick-change here -- but if you don't plan on doing that very often, you shouldn't consider it a dealbreaker.

This battery-powered DeWalt palm router eliminates the need for frustrating and cumbersome extension cords, making for a convenient and tripping-hazard-free working environment. The electronic brake increases safety even more, quickly stopping the motor as soon as the unit is shut off. A variable speed dial lets you control the RPM output to suit your specific task, and two LEDs help illuminate your work surface.

Keep in mind that this model does not include a battery, so we'd suggest this model for those who already have or plan on getting other DeWalt 20-volt tools and batteries.

I've always appreciated the rugged and durable construction of Makita tools while working on commercial construction projects, which made this router an easy choice for our heavy-duty option.

Not only does it stand up to the abuse of a busy job site, but thanks to its wide speed range, this router is also well-suited for large-diameter bits. Since it's capable of maintaining speeds as low as 10,000 RPM, it excels at creating mortises and dovetails deeper than most ¼-inch routers can. (Just remember that it's still a palm router, not a full-size, 2-hp machine, so go slow, and take more than one pass if you need to.) I also appreciate its "soft start" circuitry that slowly ramps up to your desired speed, increasing motor lifespan and reducing vibrations.

You can also get this one as part of a kit that converts this tool into a plunge router.

This combo kit gives beginners the tools they need to succeed on their very first time using a palm router. Experienced woodworkers, meanwhile, find its expansive features to be welcome additions to their roster of tools. It includes a 1.25-horsepower Bosch router, as well as a plunge router base, which features the two-handed control needed for surface detailing.

This kit also comes with an eight-piece template set, each of which assist with the most common dovetail joints and hinge sizes. These templates and the router itself each come with hard carrying cases, for keeping the pieces organized and safe when not in use.

Our testing expert, Roy Berendsohn, included this robust Flex router in this year's tool awards. Compared to 18V and 20V cordless options, this 24V model doesn't sacrifice power for portability, meaning it's a great option for woodworkers who wish to venture into more heavy-duty tasks.

The 31,000 max RPM exceeds the capability of most cordless routers, which helps you ensure maximum control when using smaller-diameter bits. A dial-adjusted six-speed control that goes all the way down to 16,000 RPMs opens the door for larger bits. This tool does not include a battery, so unless you're prepared to purchase one separately, it's best for those who already have Flex batteries on hand.

Unlike most cordless routers that don't provide their own battery, this Ryobi kit includes an 18V battery and charger at a relatively low price. It also features an integrated LED light in the base and a quick-release lever for height adjustments. Weighing just 3.8 pounds (including the battery), this router weighs less than every other cordless option on our list, which is a big plus for those prioritizing mobility over stability. This model does compromise some functionality though -- with a relatively low power output and fixed speed of 29,000 RPM -- so make sure your tasks don't require larger-diameter bits that need a slower speed setting.

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