Dewalt 618 router popping sound

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Forum topic by Craftsman70 posted 03-12-2013 02:41 PM 2382 views 0 times favorited 8 replies Add to Favorites Watch
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244 posts in 2093 days

03-12-2013 02:41 PM

I have a fairly new Dewalt 618 router that I’ve used for less than an hour all together over the past month. When using it yesterday, when bogging down it made a pop, pop, pop sound. I eased up on it and it seems to be working fine. Was that just it breaking in? Some strange artifact from the electronic speed control…. or do you think that its a sign that its going to die soon?

8 replies so far

View Grandpa's profile


3259 posts in 2644 days

#1 posted 03-12-2013 02:44 PM

It is hard to diagnose a popping sound over the internet in a letter. It could be something mechanical that is slipping.

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244 posts in 2093 days

#2 posted 03-12-2013 04:26 PM

Sorry for the poor explaination. It was definitely an electronic popping sound coming from the router electronics. I didn’t know if you could get a popping sound from the brushes when bogging down the motor. Frankly, it sounded to me like it blew a few small capacitors. But since it seemed to keep working after I eased up, I didn’t know for sure.

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Bryan Cramer

35 posts in 1879 days

#3 posted 03-12-2013 05:16 PM

My router didn’t make this sound, but the area aroungd the brushes lit up like a Christmas tree and bogged down. I had a warrenty replacement of the brushes, but it still sparks bad. Some say the speed controler is going out; it’s very common on this model. I would return it or get warrenty work done on it. It is a great router though.

-- Bryan Cramer at Great Plains Design Works

View Tennessee's profile


2862 posts in 2483 days

#4 posted 03-12-2013 05:18 PM

To me, that sounds just like a motor controller that is magbraking due to too much load to try and protect itself against too much amperage. The controller puts out a signal to the motor that simulates skipping some of the 60 cycles that the motor needs to keep speed which slows the motor and the load. Sort of like a pulsating noise, save it is the brushes on the motor having less juice than needed, and the friction of the cutter makes it skip commutator slots.
Almost sounds like a bad setting in the electronic controller. Probably not user fixable, but i don’t know.

-- Tsunami Guitars and Custom Woodworking, Cleveland, TN

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2736 posts in 2545 days

#5 posted 03-12-2013 06:22 PM

Does the speed control still work?
On both of my 618’s I heard that popping sound and the router revved up to full speed. The popping sound was the magnetic speed control ring breaking. 618’s are notorious for this and dewalt refuses to acknowledge it as a legitimate problem.

-- He who dies with the most tools... dies with the emptiest wallet.

View Tennessee's profile


2862 posts in 2483 days

#6 posted 03-12-2013 07:29 PM

Wow, Nitewalker, if that magnetic speed control ring is cracking, that is the ring that rotates with the motor to tell the controller the speed of the motor. With that defective, almost anything can happen, like go to full speed such as you witnessed. Nasty stuff. If it breaks up enough to allow little bits get into the motor, not good.

-- Tsunami Guitars and Custom Woodworking, Cleveland, TN

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244 posts in 2093 days

#7 posted 03-13-2013 04:58 AM

I took the router apart tonight and the best I can tell is that I think are corner of a brush broke off and those particals must have shorted out and then mostly burned up. I found a pile of what looked like powdered brush stuck to the electronic control board right next to the magnetic ring. I think it was just he burshes breaking in and the router is ok.

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5623 posts in 2781 days

#8 posted 03-13-2013 06:53 AM

Good to hear that your router survived. It is a great router.

-- Willie, Washington "If You Choose Not To Decide, You Still Have Made a Choice" - Rush

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