Anyone ever have this happen with their brushes. I put my last brushes to the test and when i checked them, i am surprised that the router was even running. So i broke out some spare brushes and back in business. The new set had very little use when I finished a 3-d carving this morning. When i went to start a v-carving tool path the router would not even start, even doing the F1 command it would not start (i may have listed the command wrong but it is suppose to start the router). I tapped the housing with a hammer and boom the router started. I could see all kinds of sparking in the housing a good indicator that the brushes were bad. I removed the brushes and they looked almost new. I re-installed them and started my v-carve file and the router is running just fine with no sparks. Now can anyone explain to me whats going on?