D-Handle for Compact/Trim router

thingiverse

This is my first attempt at sharing a 3-D printing model. History: A few years ago, after purchasing a CNC machine, I decided I would design a D-Handle that I could use for my Porter-Cable model 450 compact/trim router. I believe I came up with a good design, and it WORKS! I used HDPE plastic. It was kind of expensive (and wasteful) to machine on the CNC. I thought I might be able to make it on a 3-D printer, but at that time I did not have one. I purchased my first 3-D printer a year ago (March of 2022). It has been a real learning experence, I did not realize how much trouble it would be to convert my 2-D design to work for a 3-D model, but I believe I have come resonablly close. Handle: The handle is in two pieces, Left and Right, and the tolerances are quite tight, but I had no trouble fitting them together. I think the handle will work for other compact/trim routers. I decided to use 4mm(dia.) x 6mm(length) heat set inserts and 4mm x 20mm Flat head screws There is some solering/electrical work to be done, but it's pretty easy. Components I used : Trigger Switch : Fielect Electric Hammer Trigger Switch for Leiya 110-2 Tool Power Speed Control - https://www.amazon.com/dp/B083K751BD/?coliid=I2UU2IR7PS6NLD&colid=15HR3H08729T3&psc=1&ref_=lv_ov_lig_dp_it Receptical Inlet (for plug from router) : Leviton 1306 - https://www.amazon.com/dp/B003AULTMA/?coliid=I1134FDAG8RQ6Q&colid=15HR3H08729T3&psc=1&ref_=lv_ov_lig_dp_it Power Cord : Pinfox 2 Prong Polarized 14 Gauge 10ft Replacement Power Cord Pigtail Tool Heavy Duty 110V 115V 120V Supply Cable - https://www.amazon.com/dp/B08MDWDX1V/?coliid=I20OKINYNLGG0A&colid=15HR3H08729T3&psc=1&ref_=lv_ov_lig_dp_it Strain Relief : Superior Electric Boot DW Cord Protector Strain Relief Boot - https://www.amazon.com/dp/B00ZY2NPCO/?coliid=IT3FRPZ9U89A2&colid=15HR3H08729T3&psc=1&ref_=lv_ov_lig_dp_it M4 x 6mm heat set inserts : https://www.amazon.com/uxcell-Knurled-Insert-Female-Embedding/dp/B09MCWFV6V/ref=sr_1_11?crid=22RRSG0WT9C6F&keywords=M4+x+6mm+heat+set+inserts&qid=1678632364&sprefix=m4+x+6mm+heat+set+inserts%2Caps%2C102&sr=8-11 M4 x 20mm Flat Head Socket Cap Screws : https://www.amazon.com/M4-0-7-Socket-Screws-Alloy-Quantity/dp/B08BBYQZ7Y/ref=sr_1_4?crid=F19DC9GA3856&keywords=m4+x+20mm+flat+head+screws&qid=1678632524&sprefix=M4+x+20mm+flat+head%2Caps%2C112&sr=8-4 I also used some shrink tube and a couple crimp on terminals. Additionally needed are 2 square nuts (I used 1/4-20 and 10-24 metric would probably be 6mm and 5mm) and 2 flat head machine screws for attaching the baseplate. The Baseplate is sized for a Porter-Cable model 450 compact/trim router, but I believe it can be modified for other routers. I included it here as an .STL, but it should be machined from acrylic I do hope someone may find this model useful. Please post any comments.