Ok, The Bosch Colts seem to be getting worse. The first couple I used
easily ran over 750 hours continuous duty. I think I got over 1000 on the
first one. At the price I just replaced them. The last few have been
running progressively less hours before failure, and the failures have been
faster and more catastrophic with over heating bearings actually melting the
nose out of the router case (nylon press fit busing) Each one seems to last
less than the last with my most recent one failing at about 250 hours.

I'm looking for an affordable replacement.

Another similar, but better router. Maybe a PC 890?

One of the import 3 phase VFD controlled water cooled spindles?

A bigger router might be ok although I am not maxing out the horsepower of
the Colt. Just wearing out the bearings. Yes I have replaced bearings on
some, and the replacement bearings usually last longer, but once it
overheats and melts out it can't be fixed again. Well, not economically. I
did consider trying to remove the nylon bushing the bearing rides in and
replace it with a home made aluminum one that would transfer heat better.

The VFD controlled spindles will have less down time (no brushes), but I am
concerned that I'll have to redo all my calculations for lower spindle speed
(max of 24K) and I still need to know if the bearings will hold up longer,
and if they will fail in a less catastrophic and more predictable manner.
They cost more, but if I get more work out of them it might be worth it.