Bosch Switch Panel POF400

thingiverse

This is a simple solution to replace a broken switch on an older 400 Watt Bosch Handheld router with a much cheaper alternative, the actual original switch costs about 25 euros to replace with a new one. Sadly, it suffers from dust ingress and blocks the mechanism, which will save you buying a new one and replacing it with a 1 euro single panel switch. So if your Router does not work 99% of the time, it's probably the switch that has failed - just remove the router handle after unplugging the mains, and check the continuity across both poles of the switch to confirm. As I found out, you can still buy them but at an outrageous price when a normal simple panel switch will do the trick. A single throw double pole for safety is recommended, STDP. There are two ways to fix it: use the slide-in panel or drill a hole and install any small switch. Alternatively, use the insert for the standard plastic flick switch that fits in the hole I made for it. Just trim off the wings on the side of the single panel switch as the Bosch switch hole is not big enough to accommodate them. It's a tight fit, so just apply a dab of super glue to hold it in place. Remember to purchase a STDP switch to isolate the mains once turned off for safety. Solder on cables or use insulated spade terminals rated for 240 AC voltage. Enjoy your fixed and cheaper router switch like me!