Thanks Jonathan. Call it cheap thrills but I'm basically looking into some interesting little future enhancements to make to my router once I have it working to keep me occupied. I'll play around a little to see what the no load current looks like at different frequencies and take it from there. Until my spindle is actually cutting something, is there a safe way to put some load on to see what happens to that current output? The though had crossed my mind to put a thick glove on and gently apply pressure to the collet nut but I'm way too scared to be the first guy to try that :-)

Your plan of automatically varying the feed rate or spindle speed sounds like a very cool idea or maybe even just to do a estop when it figures out its about to break a certain size cutter or stall the spindle but I'll have to learn quite a bit more before I can join in on that fun :-)