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I got this router from a family member for free but the bit is stuck. It's waaaay over tightened. Trying to get it out just damages the shaft (which I already managed to do). What is the best approach to loosen this and get the bit out?

Thanks!

EDIT: Following several suggestions, I tried using the pin with a bigger wrench. I tried before but only with the supplied wrench. Here is the result. It is waaay over tightened or there is some other reason why I can't loosen it. That's is way I asked for help here.

EDIT 2: thanks for all the suggestions. I will try the different approaches and report back.

enter image description here

enter image description here

  • How did you damage the shaft? – Kris Jun 19 at 0:42
  • looks like you used an improperly fitting wrench – jsotola Jun 19 at 1:16
  • I damaged the shaft when I tried to get the over tightened bit out using the wrench supplied with the tool. I suspect that the previous user tightened it with a larger wrench and now it's way overtightened. – user2503795 Jun 19 at 1:27
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    Based on the 1st pic, it looks like the housing that holds the shaft-lock pin has cracked. Based on the 2nd pic, you've damaged the shaft. Most importantly - that shaft will be spinning around 20,000 RPM and is now out of balance due to removed/rearranged metal. BE VERY CAUTIOUS using this router. Inspect it FREQUENTLY for further damage. Be aware that vibrations could cause further damage to the shaft-lock housing. If a piece were to break off while in use it would become a missile going in a random direction. [Cont...] – FreeMan Jun 19 at 13:16
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    ... Routers are very efficient at removing wood. They are far more efficient at removing meat from fingers. Since this is a new-to-you router that, presumably, you've never used, you're not familiar with the vibration level, so you won't know what feels "wrong". Extra vibrations could cause enough damage for bit to come out at some point throwing a large hunk of sharp, spinning metal at you, your work, or an onlooker. In a desire to have you around to ask further questions, PLEASE USE EXTREME CAUTION WHEN USING A DAMAGED ROUTER and consider keeping it on the shelf as a souvenir. – FreeMan Jun 19 at 13:19
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While the other answer is correct in normal conditions - that is the purpose of the pin.

I would use a bar that fits into the hole in that shaft and a properly fitting wrench as if it has been overtightened it will need some force to undo it.

Using the normal mechanism relies on the strength of the aluminum casting which may break under these conditions. And looking at the first picture it looks as if that casting is already cracked so take care.

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enter image description here

Rotate shaft until the hole (red arrow)aligns with the pin. (Yellow arrow)Push orange button to interlock pin with hole in shaft. Use appropriate size wrench to turn locking nut(purple arrow). After a couple turns the bit should slip out of the end of the shaft .

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  • Thanks! I actually tried this without success. Not I went back with a bigger wrench and broke the pin holding thing. This thing is seriously over-tightened and I am not sure what to do next. – user2503795 Jun 19 at 4:18
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    Try heating it with a heat gun. Use some penetrating oil. Try turning in opposite direction. – Kris Jun 19 at 9:47
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    Agree with Kris, try turning in the opposite direction. You may be tighten the nut, not removing the nut. – Programmer66 Jun 19 at 14:23
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Looking closely at the threads that are showing it appears that it may be a reverse thread. (counter clockwise, it is difficult to tell for sure. I do not know why it would be, neither my dewalt nor my bosch are.)

It may also be that the collet is cross threaded.

Since the shaft is already damaged:

Clamp the router FIRMLY to a bench, clamp the shaft FIRMLY in a large pair of locking pliers (vise grips) and use a LARGE adjustable wrench (crescent wrench) with long pipe over the handle on the collet to give you leverage. When you start to turn the crescent wrench, the vise grips will turn until they hit the bench and then you can start to use leverage/muscle.

AND as Freeman stated, the future use of the router is questionable.

A note on penetrates: PB Blaster is a much superior penetrate.

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  • +1 that picture definitely makes that look left-hand-threaded (or cross threaded as you say) to me. – evildemonic Jun 19 at 19:08
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It sounds like it is very tightly stuck, in which case similar methods could work as with removing stuck nuts in general:

  1. Penetrating lubricant, such as WD40. Spray it into the nut threads and let it soak in for 15 minutes before trying to loosen the nut.
  2. Heat: use a hot air gun to warm up the nut, it should expand and be easier to remove.
  3. Impact: the idea is to mount the bigger piece (the router) into a sturdy vice, put a well-fitting wrench on the smaller piece (nut) and then give a whack to the wrench with a hammer. The sudden impact will deliver a large force that can break up whatever corrosion is holding the nut up. In your case, mounting the shaft to a vice is probably difficult, but you can experiment with some kind of strong pin in the hole to stop it from rotating.
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  • Note however that the "whack" method might damage the bearings or make the existing crack in the casing much worse. Try the other two methods first. – TooTea Jun 19 at 14:01

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