Ger21- That's a PorterCable 690 (you said PC690)? It does look a little tight there. In doubt just some cleaning and silicone can do wonders to hold the sensor, they glue huge fishtanks together with silicone and a lot of commercial products have components secured with silicone too.
Thanks Gerry for the idea about showing the PCB dimensions and mounting holes, I'll add that to the instructions, I'm also working on a "quick start guide" too.
Wow that's nice carving a box out of 1.5" clear acrylic! Sexy stuff, you should make electric guitar bodies out of that stuff people go crazy for them! If you polish it with progressively lighter wet and dry paper, lubed with vaseline, you can get it to a glass clear high gloss finish. I've done some clear gear knobs and a guitar body is on my to-do list when I get some time...
Thank you too for posting the SP.dxf file for your box.
Khalid- Good to hear you got the SuperPID delivered ok. Just let me know if you need anything.
Jay C, thank you for the pictures of the Colt router. Can you confirm that the adjustable speed router has no "click" at the full speed position (ie it has no bypass switch?). If it does not, then it needs to be bypassed. The bypass mod should be as easy as joining all 3 pins of the TRIAC. This will not hurt the TRIAC and should always be reversible.
CarveOne- Excellent! I checked your build log too for the comprehensive photos you posted.
Thanks for the tip re the fuse ratings printed on the PCB, that will be changed with the next production batch.
Revwarguy- Thanks for the Colt pictures, even though your Colt is NOT variable speed controlled it does use TRIAC electronics to give the soft start feature, and probably some type of fixed speed control. Looks like it was time you pulled the dust cover and gave it a brush out anyway!