Abstract: Improvements made to a router relate to a plunge router locking system. The locking system comprises a locking arm lever coupled to a threaded member arm which engages a plunge guide post to hold the router motor housing at a desired height above the router base when the locking arm member is in the locked position. When the locking arm member is moved into an unlocked position, the motor housing can move up and down the plunge guide post, where the motor housing is opposed by a bias system comprising a compression spring to prevent the motor housing from free-falling into the router base. Additionally, the locking arm lever can be held in the unlocked position with the use of a mating coupling member attached to the motor housing in order to keep the plunge locking system in an unlocked position.

Abstract: The present disclosure relates to a dust-collection system for use with a power tool such as a router. The system includes a router sub-base adapted for connection to a router. The router sub-base defines an opening configured to receive a cutting tool of the router. The system also includes lower and upper vacuum flowpaths. The lower vacuum flowpath is arranged and configured to evacuate dust from beneath the opening of the router sub-base. The upper vacuum flowpath is arranged and configured to evacuate dust from within the opening of the router sub-base. The disclosure also relates to a system and method for aligning a template guide.

Abstract: Improvements made to a router a relate to a switchable router brake system. The switchable brake system permits a motor brake to be selectably engaged to operate when the router motor is turned off. When engaged, the motor brake, which comprises a brake resistor being placed electrically across the motor windings, causes the router motor to stop rotating almost immediately. This feature, however, is not always desired; the switchable brake system permits the operator to engage the use of the brake only when desired, thus providing the option to selectively eliminate jerking caused electric brake torque induced in the router when the brake engages.

Abstract: The present disclosure relates to a jig saw blade clamp including a first clamp member defining a main slot. A second clamp member is positioned within the main slot. The first clamp member is moveable relative to the first clamp member between a first position in which the first and second clamp members are adapted to clamp a blade, and a second position in which the blade can be inserted between the first and second clamp members. A collar is pivotally moveable in first and second opposite directions relative to the first and second clamp members. The collar includes a cam portion that moves the second clamp member toward the first position when the collar is pivoted in the first direction, and also moves the second clamp member toward the second position when the collar is pivoted in the second direction.

Abstract: Improvements made to a router relate to a fine adjust depth stop system. The preferred router comprises a micro-adjust knob coupled to a threaded member within one of a plurality of plunge guide posts. A depth stop nut is coupled to the treaded member such that the nut travels up and down the threaded member as the mirco-adjust knob is rotated. The location of the nut within the plunge guide post defined a depth stop position for the motor housing relative to a router base. When the motor housing is located at the depth stop position, the stop point, and thus the motor housing, will move up and down relative to the base as the micro-adjust knob is rotated.

Abstract: Improvements made to a router relate to a sub-base alignment system. In a preferred embodiment, the alignment system comprises a plurality of raised bosses which are located on the sub-base at known locations and which engage a plurality of recessed cavities in the router base. Alternatively, the raised bosses may be placed on the router base and the cavities may be located in the sub-base, or a combination of boss and cavity locations may be used. The router base is positioned at a known locations relative to the center of rotation of the router bit. For example, in the plunge router shown, the base is coupled to plunge guide posts, which themselves are coupled to the motor housing at known locations. The coupling of the raised bosses with the recessed cavities places the sub-base at a known position relative to the router base.

Abstract: Improvements made to a router relates to a plunge router depth stop system. The depth stop system comprises a depth stop rod contained within a restraining collar coupled to the router housing. The depth stop rod is configured both to rotate at a fixed height above the router base and to slide up and down within the collar in order to adjust its height above the base. At an upper end of the depth stop rod, a turret knob permits an operator to rotate the rod within the collar. At the other end of the rod, a protrusion portion selection member is located to engage selectively one of a plurality of step-wise rising depth stop position surfaces located on the router base. When the protrusion portion selection member is aligned vertically above one of the depth stop position surfaces, the motor housing will plunge until the protrusion portion selection member engages the depth stop position.

Abstract: Improvements made to a router include a switching system which is part of a router handle and which operates the router motor by connecting it to an external electrical power source. In a preferred embodiment, the present switching system comprises the use of a locking lever and trigger in combination to activate the motor, to hold the trigger in a locked-on position to maintain the connection of electrical power to the motor, and to lock the movement of the trigger from occurring before an operator attempts to engage the motor. The switching system may also be combined with a preferred router handle shape in order to make the long term operation of the router and its switching comfortable with extended use.

Abstract: Improvements made to a router relate to a router chuck and collet mounting system. In a preferred embodiment, the present mounting system comprises mating a top face of a router chuck with the lower surface of an inner race of an armature shaft bearing and mating an inner diameter of the chuck with an outer diameter of the armature shaft to align the chuck with the shaft. Additionally, a cavity through the chuck may be used to accept a router bit shank so that it extends up into a lower end of the shaft in order to permit the shank to extend upward, closer to the armature shaft bearing. This arrangement reduces router bit run-out.

Abstract: Improvements made to a router relate to ergonomic router handles. The preferred router handles are generally elliptical in shape and have one end narrower than the other end. The handles are shaped to provide an operator an infinite number of angles to which the operator's hand may effectively grip the handles. Additionally the handles provide an outer surface which provides a flat tactile grip area. The combination of these elements, along with the shape and location of the preferred trigger and locking arm switch used to activate the preferred router, provides an operator, while operating the router, with the ability to find and use a handle-holding position which is comfortable for the individual user for holding the handles.

Abstract: A sander vacuum housing and pad frame system is provided for generating unique, continuous air flow for dust collection in a sander coupled to a dust collection system, while providing the versatility of a pad frame system. The system has particular application to a pad frame system for supporting sanding pads having varying characteristics, but is not limited to such a system. The system comprises a vacuum housing configured to be coupled to a motorized sanding mechanism of a sander for moving the vacuum housing in a sanding motion. The vacuum housing defines the upper portion of a dust channel. The dust channel in the vacuum housing is configured for connection to a dust collection system. The system further comprises a pad frame configured to be coupled under the vacuum housing for moving the lower surface of an attached frame in a sanding motion. The pad frame comprises a sanding pad for supporting sandpaper.

Abstract: An in-line sander comprising a sander body which houses a motor coupled to an in-line oscillating mechanism. The in-line oscillating mechanism is adapted and configured to move a sanding pad in a linear oscillating motion.A preferred pad is a profiled sanding pad coupled to the in-line oscillating mechanism. The profiled sanding pad has, in a plane substantially perpendicular to the linear oscillating motion of the sander, a particular cross sectional profile corresponding to a profile to be formed onto or to be sanded on a workpiece. The cross sectional configuration extends substantially consistently along the length of the pad, and the pad defines a sanding surface having a profile corresponding to the particular cross sectional profile. With such profiled sanding pads, sandpaper secured to the sanding surface of the pads will power sand the profile to be formed onto or to be sanded on a workpiece.

Abstract: A pocket joint cutter system for forming a pocket cut and fastener bore into a workpiece. The pocket cut and fastener bore receives a fastener such as a self-tapping screw which passes through the bore and into a second workpiece for forming a Joint between the two workpieces. The head of the fastener is held within the pocket cut in order to secure the joint. In one preferred form of the present invention, a workpiece system secures the workpiece in a predetermined position and forms the pocket cut and fastener bore into the workpiece. This preferred embodiment further comprises a bench-mounting system coupled to the workpiece system for securing the system to a bench. Using this embodiment of the present invention, the system can be mounted to a bench, and the workpiece can be brought to the system and held in position while the user forms the pocket cut and fastener bore.

Abstract: An optical system for projecting an alignment marker on to a workpiece relative to the circular blade of a power saw. The light projection system projects a planar beam of light along a plane defined by one side of the blade to designate the location at which that side of the blade will enter the workpiece. An adjustment mechanism may be included to allow movement of the light projection system so that the planar beam of light can be selectively located parallel to the plane defined by either side of the blade.

Abstract: A miter saw with an optical system for projecting an optical alignment marker onto a workpiece. The miter saw has a base, a turntable rotatably supported by the base, a fence disposed above the base for supporting the orientation of the workpiece located on the base, a support coupled to the rear portion of the turntable, and a cutting apparatus including a blade for cutting the workpiece. The cutting apparatus is pivotally coupled to the support for positioning the blade from a raised position above the workpiece to an operational position for engagement with the workpiece. The light projection system is attached to the cutting apparatus for projecting an optical alignment marker onto the workpiece so that the location at which the blade engages the workpiece is in a selectably adjustable relationship with respect to the position of the optical alignment marker on the workpiece.