DEWALT Rotary Saw DW660 Review Powerful Tool with Tool-Free Bit Change and Durability

Description

Highlights of the DEWALT Rotary Saw DW660

Testing the DEWALT Rotary Saw with 1/8-Inch and 1/4-Inch Collets, 5-Amp, Corded (DW660) gave me a solid impression of a tool designed with professionals in mind. The 5-amp motor running at 30,000 rpm is notably powerful for a cutout tool of this size. I found it effortlessly handled drywall, plywood, and even tougher materials like ceramic tile and solid birch. The tool-free bit change system is a genuine time-saver; no more hunting for wrenches or fiddling with complicated setups. I appreciated the bump-off switch, which allowed quick shutdowns without fumbling, enhancing both safety and convenience. Its slim body design made extended use less tiring, which is crucial during long jobs.

• Powerful 5-amp motor delivers impressive cutting speed and efficiency
• Tool-free bit changes simplify workflow and reduce downtime
• Bump-off switch enhances ease of use and safety

Drawbacks to Consider

While the tool mostly impressed me, it wasn’t without flaws. The corded design means you’re tethered to an outlet, which can limit mobility on larger job sites or awkward spaces. The weight, around 3.5 pounds, felt a bit heavy during prolonged precision tasks, especially when compared to some cordless or lighter rotary tools. Dust, though somewhat managed by the sealed switch, still found its way into crevices during drywall work, requiring regular cleaning to maintain performance. The depth adjustment, while tool-free, could be a little more intuitive; I had to fiddle with it a few times to get the hang of the mechanism. Also, the included collets of 1/8 and 1/4 inch limit bit compatibility; if you need larger sizes, you’ll need to source them separately.

• Cord limits freedom of movement on bigger projects
• Weight can cause fatigue during fine-detail work
• Dust infiltration requires vigilance despite the sealed switch
• Depth adjustment mechanism takes some getting used to

Ergonomic Design for Prolonged Use

This rotary saw’s slim and ergonomic body shape really stood out to me. I’ve used bulkier tools that make my hands cramp after a while, but this one fits comfortably in the hand, reducing fatigue. The 10-inch length and balanced weight distribution contribute to better control during plunge cuts or lateral slicing. I handed the tool over to a colleague who does a lot of drywall installations, and she noted the lower vibration and comfortable grip made her cutouts more precise. The rubberized cord and internal clamp also enhanced grip and durability, preventing accidental unplugging or cord damage on rough job sites.

Versatility Across Materials

In testing, this tool wasn’t just a drywall specialist. It cut through acoustical ceiling tile, cement board, Plexiglas, and even countertops with surprising ease. The jam pot construction gave it a rugged feel, reassuring me it could take the knocks of a busy workshop or construction site. Spiral bits performed well for both plunge and sideways cuts, allowing smooth transitions between different cutting angles. I tried it on some tile patches, and while it’s no replacement for a dedicated tile saw, it handled small cutouts cleanly without chipping the edges. This versatility makes it a handy addition for electricians, carpenters, and DIYers alike.

Price Performance: Is It Worth It?

Considering the robust 5-amp motor, tool-free bit changes, and durable build, this rotary saw offers solid value for professionals who need a reliable cutout tool. It’s not the cheapest on the market, but the price-to-quality ratio seems justified based on how many materials it can handle and the time saved during bit changes. If you’re an occasional user, the corded nature might feel restrictive, and there may be more budget-friendly options. However, for someone doing frequent drywall or tile work, the investment pays off in speed and durability. The included 1/8 and 1/4-inch collets and bits also add immediate usability without extra purchases.

Product Comparisons with Other Rotary Tools

Comparing this tool to popular competitors like the Fein or Bosch rotary cutout tools, the DEWALT stands out with its higher motor power and speed. The Fein model is praised for precision and quieter operation, but it lacks the raw cutting power this model brings. Bosch tools often have cordless models with better portability, yet they can’t match the consistent power of a corded 5-amp motor. The DEWALT’s dust-sealed switch and jam pot construction contribute to longer tool life, especially in dusty environments. However, some competitors offer more collet size options and better ergonomic features for fine detail work. For heavy-duty cutting and jobsite toughness, the DW660 is a solid choice, but if cordless freedom or ultra-light weight is your priority, other brands might edge it out.

Benefits of the Tool-Free Bit Change System

I can’t stress enough how much the tool-free bit change revolutionized my workflow. It allowed me to switch between the 1/8-inch drywall bit and the 1/4-inch general-purpose bit in seconds without interrupting my momentum. This feature is especially handy when alternating between cutting drywall sheets and making smaller, more detailed cuts in plywood or tile. The spindle lock mechanism also helped secure bits effortlessly, preventing slippage during intense cutting sessions. In comparison, older rotary tools with wrench-required bit changes feel archaic and slow. This convenience factor alone makes the tool feel like a modern upgrade for anyone tired of fumbling with tiny wrenches on the job.

Areas for Improvement in the Dust Management

Despite the sealed switch designed to keep dust out, I noticed some dust buildup around the motor housing and vents after repeated use in drywall environments. This means maintenance is necessary to keep the tool running smoothly. A better dust extraction system or compatibility with external vacuum attachments would raise this tool’s usability on dusty job sites. Additionally, the depth adjustment, while tool-free, could be more robust; I occasionally felt it shift slightly during aggressive cuts. Improving the grip and precision of this adjustment would benefit users who need exact cutting depths for electrical boxes or plumbing access points.

Testing this powerful rotary saw made me appreciate how much thoughtful design goes into tools meant for pros. Its combination of power, ergonomic design, and quick bit changes offers a compelling package, though some trade-offs like corded operation and dust management require consideration. For those who regularly cut drywall, tile, or plywood, this tool proves to be more than capable, but casual users might find lighter or cordless alternatives easier to handle.

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