Sorry I got a bit lazy and my post was unclear, I meant buying a new router to make the router / spindle table.
Here’s some options I’m considering:
Amazon.ca
dwp611 dewaltAmazon.ca
dewalt 2hp routerAmazon.ca
makita 2 hp routerAmazon.ca
smaller makita routerAmazon.ca
(20v cordless dewalt)Amazon.ca
2.2kw spindle (already own similar, downside is 20amp req which I’d have to run wiring for)
I have that cordless Dewalt. Cordless is great for mobility. If you are mounting in a table I would not go that route though. You will have to get under there to swap the battery all the time.
You are probably going to want to take bigger bites with a fixed table and that won’t be ideal for the cordless model.
Ok, good points! I’ll pass on the cordless router.
I found this jig that looks super interesting for cleaning up rectangular pieces.
It seems I just stick my workpiece to the table with double sided tape, then setup the jig and it should easily clean up all the sides?
Also for the bits I’m buying I want downcut, since I’m doing flush trimming work??
https://www.aliexpress.com/item/1005005875147066.html
Here’s a video of a DIY jig. Seems perfect to make on the Shapeoko: https://www.youtube.com/watch?v=DlFJP89Ojmc
The only reason I’d maybe favor the jig over templates, is that there will be custom sizes from time to time which could be anything and having that variability would come in clutch.
For a router table application you want a bigger router. There are basically 3 types. The trim router 1-1.25 HP, the 2-2.5 HP and then the 3 HP and up. I have all of these and in my router table I have some Porter Cable 890 routers. Porter Cable is not making routers any more. I have had Bosch 1617 and dont care for them because they have their own router template and not the Porter Cable type. The Bosch 1617 was ok but I just did not like the ergonomics of it. The Dewalt is a great medium size router and accepts the Porter Cable style template guides. The Makita is a good router but from what reviews I have read their quality has slipped the past few years. The Skil routers have pretty good reviews. The good thing about the medium size routers is they all have the 3.5" router base diameter. The trim routers are 66 and 69MM mostly but some other sizes. The big 3HP and larger are 4.2". So if you are going to get a router table and a lift then the medium has the most selection of router lifts. Many of the medium routers do not require a lift and are adjustable from above the table with the router base installed and a hole in your router plate to adjust them. However the router lifts are much more precise in making adjustments because they usually have a scale that is able to zero and make precise adjustments for height.
So there are a lot of medium size routers that are good but make sure you get the plunge kit type routers because they come with both a plunge base and a fixed base. The plunge is handy when you need to make repeated cuts at various depth. A fixed base router you have to cock the router to the side to plunge in and that can lead to problems. There is a place for both types of bases but the plunge is very versatile because you can plunge or use it as a fixed base.
If all my routers disappeared I would likely buy the Dewalt or the Skil medium routers because of the quality of the products and the compatibility with most router lifts. Most modern routers have the variable speed and you need to adjust speed depending on the diameter of the router bit you are using.
You had listed some bearing router bits above. Look at Infinity Tools and the Whiteside bits. I like the Infinity bits because you can get a single bit with both a top and bottom bearing. This makes template routing much easier to do instead of having to have both a top and bottom bearing bit. The Ultra Shear from Woodpeckers looks great but they want and arm and a leg for their stuff.
I don’t think that jig does what you expect. It looks
Like it is for routing out rectangular pockets, not cleaning up edges of existing pieces if I understand it.
Appreciate you sharing your experience and insights, genuinely helped me a lot in making a decision. I strongly considered the variable speed 2 1/4 HP Dewalt router, that seems to be my best option but it’s $300 and I figure it’s going to be upside down having aluminum dust falling into it all day (might break fairly quickly) so it’s best to buy a cheap used one while I figure out my setup. I found myself delaying and researching too much and had to pull the trigger on something…
Sooo I bought a comparable used Mastercrap Maximum 2 1/4 HP router for $70, it sells new for $230 and looks lightly used, it’s a decent deal. Generally I don’t buy anything Mastercraft, it’s a terrible brand but the router actually looks like it might be ok. The RPM range is 11-20k which seems good. I’ll need to figure out a way to keep aluminum out of it when it’s upside down.
I’ve got a used table saw top that I’m going to try to convert into a router table. I’ll try to get it finished tonight. The nice thing is it has some threaded holes already for mounting but it’s not meant to hold the weight of the router so I might need to mod it and put a new top or something, not sure yet.
What you mentioned about tilting the router and doing a side plunge was actually a major concern for using that adjustable jig I linked. It made me reconsider if it will actually work well. It made me realize if I want to try that setup I 100% NEED the plunge attachment.
I think my best bet is to stick with templates for now, it’s not the end of the world to cut out a new acrylic template. Pretty fast actually. Eventually I’ll try out the jig but for now I’ll stick on the proven path.
Thanks for the bit recommendations, I’m going to place an order tonight. This bit in particular looks interesting: https://www.infinitytools.com/mini-mega-flush-trim-router-bits
Yea you’re right its designed for pockets but I figure if I leave an extra 3-4mm of material and try to center the workpiece, clamp the jig around it, then plunge and hug the outside edges of the jig it should give a good result. I’m not sure though, I’ve actually never used a router manually before 
I’ll pass on the jig for now since I’d be inclined to make one and it’s a huge time sink. Gonna use templates it seems they get really nice results.
Here’s the router table I made. I’m going to make either a steel or 420 stainless steel surface plate and stick it to the wood with embedded magnets. The vacuum works well. Going to wedge a piece of foam in the hole with a slot for the end mill to go through, that should handle any dust issues.
Overall pretty happy with the setup except I made the table too high 
need to modify it and drop it down 6" to be able to comfortably use it in the shapeoko enclosure.
Good luck with the dust collection. Routers are notorious for spewing dust every where. Let us know if your solution works. The router has air flow from the top to the bottom of the router from the internal fan in the router. Some dust and chips still get into the router internal body but it is made for that. So between the air flow of the router and the dust collection it might work pretty well but over the many years the best laid plans of mice and men go awry.
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