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Design Concept
This model is a replacement lever designed for a Skil router, created to solve a very common failure point in the original mechanism.

The original lever often breaks internally but remains attached due to the embedded brass insert and screw. This design allows you to reuse that original brass insert and restore full functionality with a stronger, printable part.

Important:
In order to install this replacement, you will need to break or remove the remaining plastic from the original lever (if it hasn’t already failed) to extract the brass insert/screw inside.

Once removed, this printed lever is used together with that original brass insert, ensuring a secure and durable fit.

The design is compact, reinforced around the screw area, and optimized for strength in the direction of use.

Print Settings
Material: PLA (PETG recommended for higher durability)
Layer height: 0.20 mm
Infill: 40–60% (for strength)
Supports: Not required
Build plate adhesion: Brim optional
Print orientation: Flat on the build plate (as shown in the model)

For best results, increase wall/perimeter count (at least 3–4 walls).

Assembly
Remove the broken/original lever from the router.
Break or cut the remaining plastic carefully to expose the internal brass insert.
Extract the brass insert and screw from the original part.
Insert the brass piece into this printed lever.
Reinstall using the original screw.
Make sure the insert sits firmly in place before tightening.

Notes
Designed specifically for repair purposes using original hardware.
PETG or similar materials are recommended if the router is used frequently.
Avoid over-tightening to prevent stress on the printed part.

Skil 1831 Router Lever Repair (Reuse Brass Insert)

0.2mm layer, 2 walls, 15% infill