I initially used one of these (very similar internally to the Mafell) on my Shapeoko
As Will says, these are 43mm clamping ring and need a custom mount, I purchased one on eBay and modified it. The other part of the problem is that they mount very close to the collet so you can’t reach down to the spoilboard with shorter bits, which leads to further mount and Z axis customisation.
However, after listening to it scream through the ear defenders for enough time to make me want to go full Van Gogh I gave up and just bought a water cooled spindle.
I have not felt power limited with a trim router, the Kress or the 2.2kW spindle, the only major difference has been that I can run really low speeds on the big spindle and have enough torque to work, e.g. drilling ops.
You can get GPenny in 65mm 800W water cooled, apparently a new 1.2kW water cooled
and 1,500W air cooled
But I don’t think power is the constraint on a Shapeoko machine.
It’s worth bearing in mind that you need to wire these things up yourself, they are not your regular trim router. If you want something that just plugs in and goes, wait for the Carbide spindle kit, use a trim router or buy the Kress / Mafell and put up with the noise.
You shouldn’t be having router failures, most people don’t so a new router is probably the best place to start.
Like @LiamN says, if you want something plug and play, wait for the Carbide 3D spindle upgrade. I have personally upgraded my SO3 with an 800W water cooled spindle from GPenny. I love it but it isn’t plug and play.
The grease in my GPenny unit wasn’t great either. It started making noise so I replaced it with proper high speed spindle grease and it has been great since. I pulled out as much of the original grease as possible when I did this and it was pretty lumpy.
Do you know when this is coming out? I saw some posts from March saying it was coming “in a month”. I would much rather use something official, but I also need to have a working machine now, not wait. The easiest path to having a working machine is the one I will take.
I am fine with the noise, it is the mounting I’m worried about for the Mafell. I don’t really want to make my own mounting plate.
The grease in mine had almost completely dried out, there was a white crust on the inside of the bearing seals and basically nothing else so a syringe and super-lube it was. I think I’ve got some runout now but it was a cheap no-name. I’ve got another in the cupboard for when this one finally fails.
I have the Huanyang 800W water cooled spindle (https://smile.amazon.com/gp/product/B077BY11Q3). I went with the CW5200 for cooling as my garage gets quite hot in Texas. I figure if I ever add a laser cutter, I could probably setup a manifold and cool both units off the same chiller… I also used 8mm OD silicone tubing, and I was able to route the power cable (16/4 SOOW) and both tubes through the drag chain without pinching.
I don’t think power becomes is the limiting factor. The cutting forces and power consumption are proportional so you’re limited by whichever is the weakest link. Hint… it’s the cutting forces. You can decrease the cutting forces with larger diameter end mills, but then you need to get a larger collet. An ER20 spindle would be nice, but those are all the larger diameter size.