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Rack-and-Pawl Plunge Router: The Motor Rides One Post on a Spring and Steps Down a Tooth at a Time (Carter, 1925)
Ray L. Carter · Public domain
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13. Novemba 2026NO
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Rack-and-Pawl Plunge Router: The Motor Rides One Post on a Spring and Steps Down a Tooth at a Time (Carter, 1925)

Ray L. Carter of Syracuse, New York, improved his 1924 router with US 1,565,790, dated 15 December 1925. The motor's holder now slides up and down a single strong post on a large round base, and a spring inside the post holds it up off the work. Each press of a lever moves the holder down one tooth of a rack, so a deep cavity is cut in stages. A locking pawl holds each step. Gauge nuts on a plunger stem set the final depth, and pressing the pawl's foot lets the spring lift the cutter clear. We reuse our 1924 router's printed motor casing in a printed holder on a square steel post. The sizes are ours.
Juu
About 3 days

Maagizo

1

Cutting deep in stages

Inapakia daftari la Jupyter…
2

Read US 1,565,790

"By this arrangement cavities of considerable depth may be routed by successive stages wherein each stage represents the normal depth the tool is designed to cut."
3

The motor and its casing come from the 1924 router

Print the casing and fit the motor, collet and switch exactly as in Carter's 1924 router; here the casing screws into a holder on a post instead of into a base.
4

Print the holder

The holder 7: a split ring threaded for the 1924 casing, clamp lugs for a thumb screw, and beside it the guide 7c with a square opening for a 1 in tube, a recess for the gib plate, two set-screw holes and the rack 17 of 3 mm teeth on its outer face. Print it rack upright. PETG, 0.2 mm layers, 40 % infill, 5 walls; no supports.
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5

Print the base

The base 9: a round plate 170 mm across with a 50 mm opening, and the boss 9' with a square socket for the post and a hole for its cross bolt. Print it plate down. PETG, 0.2 mm layers, 40 % infill, 5 walls; no supports.
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6

The hollow post 8

Cut 1 inch square steel tube 200 mm long. Saw and file a slot 8b 6 mm wide and 100 mm long down the middle of one wall, starting 40 mm from the top. Push the post into the base's socket and bolt it through with an M6 bolt and lock nut. Drop a compression spring 10 into the post, then a plunger 13: a block of flat bar that slides in the tube, tapped M6 on its back for the screw that runs in the slot, with an M6 rod 13' standing up from it. Screw a flat-bar cap 12 across the post's top with a hole for the rod, and run two gauge nuts 14, 14' onto the rod above it.

Vifaa kwa hatua hii:

Mild Steel Square Tube 1" x 1"Mild Steel Square Tube 1" x 1"1 kipande
Pau Bapa la Chuma LainiPau Bapa la Chuma Laini1 kipande
Seti ya springi za kubanaSeti ya springi za kubana1 kipande
Fimbo yenye nyuziFimbo yenye nyuzi1 kipande
Nati ya pembe sitaNati ya pembe sita2 vipande
Mkusanyiko wa bolti za pembe sitaMkusanyiko wa bolti za pembe sita3 vipande
Nati ya Kufungasha yenye NailoniNati ya Kufungasha yenye Nailoni1 kipande

Zana zinazohitajika:

Msumeno wa chumaMsumeno wa chuma
Seti ya tupaSeti ya tupa
Kibano cha meza ya kaziKibano cha meza ya kazi
Kekee cha NguzoKekee cha Nguzo
Seti ya vichimbuziSeti ya vichimbuzi
Seti ya kukata nyuzi za skrubuSeti ya kukata nyuzi za skrubu
Mpini wa kukata nyuzi za ndaniMpini wa kukata nyuzi za ndani
Spana inayoweza kurekebishwaSpana inayoweza kurekebishwa
Miwani ya usalamaMiwani ya usalama
7

Holder on the post

Print the holder and base. Lay a strip of flat bar in the guide's recess 15 as the gib plate 15' and run two M5 set screws 16 against it, one with a wing nut on its head to lock the holder by hand. Slide the guide down over the post and fix it to the plunger with an M6 screw through the slot. Set the screws so the holder slides freely without rattling. Screw the 1924 motor casing into the holder and lock it with an M5 screw and wing nut through the lugs.

Vifaa kwa hatua hii:

Uzi wa PETGUzi wa PETG1 kipande
Pau Bapa la Chuma LainiPau Bapa la Chuma Laini1 kipande
Skrubu ya kubana yenye ncha ya kikombeSkrubu ya kubana yenye ncha ya kikombe2 vipande
Nati ya mabawaNati ya mabawa2 vipande
Skrubu Yenye Kichwa cha SoketiSkrubu Yenye Kichwa cha Soketi2 vipande

Zana zinazohitajika:

Printa ya 3D ya nyuzi (FDM)Printa ya 3D ya nyuzi (FDM)
Kifaa cha kuondoa ukingoKifaa cha kuondoa ukingo
Seti ya funguo za pembe sitaSeti ya funguo za pembe sita
Kipima-unene cha dijitali cha inchi 6Kipima-unene cha dijitali cha inchi 6
8

Pawls and lever

File a pawl 18 from flat bar with a hook 18' at its top to catch the rack's teeth, and a locking pawl 20 with a tooth 20' at its top and its lower end bent out as a foot 20d. Pivot the locking pawl on the base's boss with an M5 screw, held against the rack by a spring-steel leaf 20b. Pivot one end of a lever 19 on the boss and the pawl's lower end to the lever partway along, with a second leaf 20c holding the pawl to the rack. Each press of the lever's handle pulls the holder down one tooth, and the locking pawl drops in under it.

Vifaa kwa hatua hii:

Pau Bapa la Chuma LainiPau Bapa la Chuma Laini2 vipande
Utepe wa chuma cha springiUtepe wa chuma cha springi1 kipande
Skrubu Yenye Kichwa cha SoketiSkrubu Yenye Kichwa cha Soketi3 vipande
Nati ya Kufungasha yenye NailoniNati ya Kufungasha yenye Nailoni3 vipande

Zana zinazohitajika:

Msumeno wa chumaMsumeno wa chuma
Seti ya tupaSeti ya tupa
Kibano cha meza ya kaziKibano cha meza ya kazi
Kekee cha NguzoKekee cha Nguzo
Seti ya vichimbuziSeti ya vichimbuzi
Spana inayoweza kurekebishwaSpana inayoweza kurekebishwa
9

Rout a deep recess

Fit a straight bit. Set the gauge nuts so the plunger's rod stops on the cap at the depth wanted. Clamp a board, rest the base on it with the cutter clear, switch on, press the lever once and move the router across the area; press again and repeat, until the nuts stop it. Press the locking pawl's foot and the spring lifts the cutter out.

Zana zinazohitajika:

Seti ya vichwa vya mashine ya kuchongaSeti ya vichwa vya mashine ya kuchonga
Ubao wa Mti MgumuUbao wa Mti Mgumu
Kibano cha upauKibano cha upau
Miwani ya usalamaMiwani ya usalama
10

Troubleshooting

Plunge router troubleshooting.

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11

History and honest limits

**Ray L. Carter** of Syracuse, New York, US 1,565,790, dated 15 December 1925, filed 21 March 1925, improving his US 1,514,894. He describes a holder "formed at one side with a guide portion having an angular vertical opening, for slidably mounting the holder upon a pedestal or post of substantially the same angularity", a coil spring housed in the pedestal, a ratchet rack and pawl to move the motor step by step, a locking pawl, gauge nuts, and a plate with set screws to take up wear. His post is triangular and cast; ours is 1 inch square steel tube. His holder and base are metal; ours are printed PETG. His motor ran on mains; ours is the small DC motor of our 1924 router. The sizes are ours.

Vifaa

12

Zana Zinazohitajika

16

Faili za muundo

2

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Screw-Depth Portable Router: The Motor's Threaded Casing Screws Into a Split Base, One Turn per Sixteenth (Carter, 1924)

Screw-Depth Portable Router: The Motor's Threaded Casing Screws Into a Split Base, One Turn per Sixteenth (Carter, 1924)

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