Just an update for anyone else considering this. I order a PC 450 (twin of DW611 w/o the speed control) and gutted it last night. After poking around in its innards it turned out to be pretty simple to remove the soft start TRIAC and connect the switched leads directly. I used crimp/solder connectors in case I ever want to reverse the process. The unadulterated guts:
Soft start removed and leads reconnected:
Without the TRAIC there is a ton of room to nest the wiring out of the way. Here’s a glimpse of the router shaft target for the speed sensor:
The poly tube installed w/ CA glue. Sighted thru it with a light and it’s a bulls-eye on the router shaft:
I was simpler that I had expected. Tonight I hope to get the S-PID rigged up on the bench to test and adjust it before I start assembling the control box.
RMW