I needed a way to improve the dust collection on my Dewalt sliding miter saw. It is the saw used in the miter saw station build. My problem was that in order to mount the saw with some room left on the bench, the build in dust collection had to be removed.
I started by designing a prototype in SketchUp. The first prototype worked well, but could be improved by using more of the 4″ dust collection system. I redesigned it to use two 2.5″ ports, split off of the 4″ line.
This prototype worked fantastic, but kept the saw from turning to 45 degrees. Back to the drawing board!
The final prototype was done in Fusion360 and moved the 2.5″ dust ports forward and added better wings to catch as much of the sawdust as possible.
It works well. I printed the final out of PETG, using stronger settings than normal, resulting in a 28 hour print time.
Since some folks have asked for it, I have made a left and right STL for those with smaller printers. I have not printed them.
Hi, Jervin. I can’t wait to try this on my DeWalt saw as well. Elegant. *(and the dust collection is a mess). Do you by chance have an STL for the second piece as well (the two small ports to the 4″ port)? Thanks.
Thanks. It works great for 6″ or less. This past week while cutting some 10″ boards, I noticed that it was not working as well as I would like. I am going to make a few tweaks that may include a “traveling hose” that flows from the device out with the sliding arm.
can you send me a picture? issehd@icloud.com
Of the finished item? I don’t have any other than those on this page, but if there is a feature you are trying to follow I can take one and send it to you.
Hello Jervin, I have the same Dewalt saw and will have a company print the shroud for me. Very nice design, thank you! Is the V9.stl the latest with the “traveling hose” design to work better for 10″ boards? If not, have you designed that version yet? Thank you
The one linked is the latest and last…it is the one I use in various videos you can find. As to the traveling hose, I have taken two passes at something, but so far nothing works as well as the one shown here.
Okay, thank you for the response. I am going to have one made using PETG but the most they will infill is 80% and not 100%. Do you think 80% infill will be enough?
Even 80% is overkill. I make mine out of PETG and think I use less than 40%. Infill in the “bottom” of the print that becomes the “top” of the part helps as you have to cut through it with the “first cut” and it can chip etc. Don’t be alarmed when the cut makes a ragged edge in the PETG.
Who/where are you using to print this for you? I too need one for my station.
Hi Jervin, Thank you so much for sharing your work with us. Where I can download the adapter that connects the two 2.5″ ducts to the bigger one? I mean the part that is the picture with the dust collection system. I can not find it on your downloads. Thank you in advance for your help.
I did not put the adapter up on the site as it is not worth it to print. https://www.rockler.com/rockler-4-to-2-1-2-dust-collection-y-connector If you still want to print your own, let me know.
Thank you very much Jervin! Makes total sense.
Looks awesome! Really like it. Makes me wish I had 3D printer.
Do you sell them? If so how much?
Alas, I do not. It is a big part, takes 18 hours to print and is generally a pain in the but. It is not as effective for wider boards, but I am working on a tweaked design that should make that better.
Looks good. If you come up with another prototype please do a video. I just purchased this saw last weekend so it will be replacing a 16 year old Makita 1013L with no dust collection capabilities at all. I guess I am with the others, need to find someone with a 3d Printer. I can live with some dust from 10″ boards if it works great for 6″ or less.
This is amazing, James. Very solid work. Working with a friend to get one printed. I’ll let you know how it works!
I am more and more happy with it, especially after getting my dust collection system working better (had an old felt bag and vented it outside which doubled the volume it moved).
HI Jervin,
I have a prussa Mk3 and the footprint can’t accommodate the full print. Is it possible to get your help and splitting this 3d object?
Your slicer (I use cura) can print just half.
I have a friend who is going to try to replicate tis in aluminum. Thoughts? I don’t have a CAD or the software that opens your downloads. Any chance of getting the dimensions of your final version?
The file is just an STL, a standard shape file. If your friend had CNC capability, he will be able to open it. I suggest you see if he can open it, but I can give you any dimension you seek.
Hi there, thanks for the video. It’s a fantastic idea. I had one built and looked to be doing well. I made the 0 and 22.5 degree cuts, but when I tried the 45 degree cuts the top de-laminated. I’ll have a another built but with 100% fill. Hopefully that’s gonna work out better. Have you had any such experiences or do you not use the shroud for 22.5 degree cuts?
Good morning. I am on my second one and do generally only 90 degree and an occasional 45 degree cut. A lot depends on how you slice it (the process of preparing it for print). My “final” is made of PTEG and uses four layers for faces (so the top has 8 total) and I use a heavy infill as you have suggested so that after the cuts are made, there is still some strength. In one test unit a pie wedge eventually came out of the unit, but it did not seem to alter its function.
Would you consider selling these parts. I don’t have a way to print them but could really use them.
There are lots of places that can print the part. I only have one very old printer and it is a 24 hour print job.
How large is the piece for the mitre saw? I am thinking about buying a 3D printer….is this one large enough? https://www.amazon.com/ANYCUBIC-Leveling-25-Point-All-Metal-13-8×11-8×11-8inch/dp/B09QGTYW3R/ref=sr_1_1_sspa?keywords=Big%2B3D%2BPrinter&qid=1658882868&smid=A1A5FQE7R5RISB&sr=8-1-spons&spLa=ZW5jcnlwdGVkUXVhbGlmaWVyPUEyU1AyWk1NQ0xRVVVWJmVuY3J5cHRlZElkPUEwMjc5OTM3MkE0MzNROUI5STU5QyZlbmNyeXB0ZWRBZElkPUEwNzI3NjQ3M1U3Mk05WFNYOUpTMiZ3aWRnZXROYW1lPXNwX2F0ZiZhY3Rpb249Y2xpY2tSZWRpcmVjdCZkb05vdExvZ0NsaWNrPXRydWU&th=1
That should be plenty big enough. The printer I printed mine on was only about 12″ X 12″. You do have to position it at an angle (diagonally on the build plate).
How large is the piece for the mitre saw? I am thinking about buying a 3D printer.
It is 311mm wide, 114mm deep and 94mm tall. I print it on 300×300 printer positioned diagonally on the build plate.
Fabulous design! I’ve printed one but I can’t figure out how to best secure it to the saw. Are you using glue or a mechanical fastening solution? Any tips would be appreciated.
I use the white construction adhesive. Seems to work great.
Ace, thanks for the tip, will give it a go!
I’m about ready to get a new miter saw, and had settled on the Hercules brand from Harbor freight. It’s a lot less money than the Dewalt. What was the radius of the Dewalt saw that you measured? I have friends who can 3-D print for me, but I want to make sure that your file will fit my saw.
Hello – I really like your dust collection mod for the Dewalt miter saw. I would love to print one but my ender 3 is too small to print the entire thing, I might be able to print it if I could cut the outlets off. I tried to download the fusion 3d model but I could not get Fusion 360 to read it. IS there a file you could email me that would open in Fusion 360? Thanks in advance. – Mike
Your slicer (I use Cura) should be able to split it down the middle for printing.
I just printed it on an Ender 3. I rotated it vertically and set the z axis to – 50% of the total height. This allowed me to print half of it, then I rotated it 180 degrees to print the other half. You are left with 2 very good faces to glue the 2 halves together.
Perfect. I have been advising folks that their slicer program of choice could easily split it. I hope it works for you.
Hello currently getting one made just curious if I’ll be able to hook up to my shop vac? Awesome design any advice will be appreciated.
I have run mine on a 2.5″ hose from a shop vac. You will just need a “Y” fitting to split the hose coming off of the vacuum.
Do you have the second file in an stl? My Father-in-law wants me to print this for him but I can’t upload the second file. Thanks.
Do you mean the splitter?
There are two files, an STL and a Fusion 360 file. I think the STL is in inches, but Sketchup exports them strange at times.
I know nothing about 3D printing but am trying to get a quote for printing this.
One of the questions I’m being asked is for the units of measurement: mm, cm or inches.
I also want to make sure that I’m only asking for a quote on printing the collection unit, and not the splitter.
You have two different files – do I use the v9?
Thank you so much, this is exactly what I’ve been looking for.
Well, the estimate was $340! I’m going to try to fabricate something similar from a rubber dog bowl.
That is stunning. It takes my machine 26 hours to print it and 1/2 spool of filament. I could see it being $60, but wow.
First thanks for the design. I am debating splitting and printing it on my printer or just having a shop do it. Quotes on cloudcraft to have it printed range from ~$40 with shipping for PLA with 100% infill to around $100 for ABS or $150 for PETG all with 100% infill. 80% was a marginally less expensive.
I would split it and print it. Your slicer should be able to split it.
Hello Matthew, Do you have the link to cloudcraft for printing? I am interested in the ABS 100% infill and the only company I can find so far charges nearly 4 times that! Thank you
would you have the stl file for the splitter? cant open the fusion file
If I were to do it again, I would not print my splitter, but buy this: https://www.rockler.com/rockler-4-to-2-1-2-dust-collection-y-connector If you do want to print it (I bet the rockler one is more efficient), send me your email and I will mail you the STL.
its ckasher145@yahoo.com, thank you
PLEASE PLEASE PLEASE may I also have the file for the spliter? I can print it myself then.. perfect! Mail@d8ve.co.uk
Thank you, love the work.
Your slicer should be able to split it. I will see if I can find my split STLs and email them.
Hi Jervin. Was wondering if you could email me a copy of them also. I’m new to 3d Printing and have failed 2 attempts because I tried printing it flat (with the top down on the bed) and it messed up after doing the top so I stopped it.
STLs would be greatly appreciated.
Thanks
Sorry I missed your post. For some odd reason the website software buried about 15 posts. I can email you the file. What is your email?
I have a double compound Dewalt 706. I do not have a printer to make this. Would you be interested in making one for me and if so what would it cost?
Thanks
Andy
I don’t have the capacity to print them commercially. I have one very very old 3D printer. I am building a new printer, so that may change.
Are you guys printing with supports?
I print it upside down, so the only supports needed are in the tubes.
hey where can I buy one of these I own a dewalt compound bevel miter saw and need this alot because the dust in crazy thanks
Most folks take the STL file and send it to a person that does 3D printing.
can you post the STL file for the 2 1/2″ x 4″ hose adapter (the one you show on the vide) on your site please???
I have not posted it as you can buy one cheaper than printing it: https://www.rockler.com/rockler-4-to-2-1-2-dust-collection-y-connector
If you still want it, just say so and I will find it.
Thanks for the excellent video and digital files.
I’ve just started to make this, but had a question regarding the dust port diameter in the fusion file. In Fusion 360 they’re measuring 2.25″, so are they undersized for a 2.5″ hose? Or is my scale off somehow? Thanks!
It has been a while since I did the design, but I think I used 2.25 as that is a good fit for the internal diameter of standard 2.5″ hose.
Hello has anyone checked that you’re aware of to see if this will fit the non-sliding DWS716 12 inch. My question is the radius behind the fence and the heights the same. Hopefully making a compatible with a non-sliding version.
I listed the radius I used in one of the comments.
Well I didn’t see that and the one I had printed is to big. Could you help me scale it down to a smaller size.
Can you get an accurate measurement of the saw’s chamber radius?
I will try tomorrow night out of town now. And also doesn’t mate up with the back of the adjustable fences I think it’s going to need its own fence at least an inch or two in from the sides. Also it looks like you removed all the factory Dewalt dust collection components on your saw. I have not removed mine just yet to see if the height will interfere with the full down position.
The internal diameter of the chamber radius is 6 1/4 inches
Hello there, I am a Legally Blind woodworker and have no access to a 3D Printer. Would you consider selling me one of your printer collector for the Dewalt? Mine is a Double Bevel saw if that makes a difference. Please let me know if you can and if so what the price would be. My email address is as follows: Adirondackbuilt @gmail.com
Thank you ,Lance Chase
Any chance someone is printing these items and selling them? I don’t have a 3D printer…
Hi Tim-
If you are still looking for one of these I could print one for you. I just made one for myself.
Let me know!
-Aaron
Hey Aaron, how much do you charge? Thx
Sorry, I just saw your reply. Shoot me an email – aaron@fourpointo.com
Hi Aaron. Just wondering if you could help me out. I just purchased Anycubic Kobra Max and tried printing it (flat) but it did the bottom then was a mess (string) as it started above that (ports). Reading here I see I need to print it vertically, and some people cut in in half.
I have now placed the stl file in ultimaker an placed it vertically and set it on the base but it is on a slight angle because of the ports are angled. OR should I cut it in half and print it with the cut half down and the port up top?
I am totally new to 3d printing and am learning. Have no idea about supports yet.
Anyways any advice help would be greatly appreciated. Thanks
To fit this dust collector did you remove the
part behind and next to the blade called
SA REAR GUARD AND DEFLECTOR SERVICE”
Also called rear dust guard. It was the same part recalled this year because the ones made of plastic would break and get flung by the blade and cause lacerations. I’m thinking the only way to efficient get rid of the dust is the remove this part and build something like your design. Thanks!
https://www.dewalt.com/miter-saw-recall
I “think” so.
Hi I would like to talk to you about this but i would like it to be out side of the this chat can you email me so i can send talk to you with out other reading it.
I thought my email was someplace on this site…but regardless you can reach me at james@kites.org
I am so excited to have stumbled across this! My problem is I have a very small shop and just don’t have the room it takes to connect a hose off the rear port. I was just on the verge of downsizing to a Kapex but am considering this instead. Are you still Lapp with and actively using this solution 2+ years later?
On the whole yes. It is better than stock in my opinion. I am on my third one. They get cut up and abused and a fresh one now and then is a good thing.
Help? I have split the file in half and it is now a G-code file in Ultimaker. It is vertical but the wide part (middle of original design) is sitting on the base with the hose connection port up top pointing up.
Is the this proper way to print it or should I rotate it so that the hose port is flat on the plate?
Would I need supports anywhere?
Sorry for my lack of knowledge as I am a newbie to 3d printing
Thanks to one and all for any help provided.
Just want to Thank Jervin fo posting the split files. I figured out how to add supports and followed your advice on putting it vertical. The right one is printing now as I type and its looking pretty good. Some stringing is happening but nothing very serious.
Just got both parts printed out and glued together. Looks great. Only thing I found was that the dust hose ports do not snugly accept a 2 1/2 inch (63.5mm) hose as the outside diameter is 2.25 (57mm). Can tape it/clamp it on or maybe make an 2 1/2 inch to 2 1/4 inch adapter.
This was my first real 3D print. Learned a lot and much more to learn.
Thanks again Jervin. Can’t wait to double tape it on and give it a try.
I am sorry I missed your post! The comment system on this hosting software is strange. Regardless, thanks for sharing. I may make a better fit if I ever get around to changing it, but also note how tight the hose is to the fence, so I make it as small as I could and still work.
Has anyone successfully found an online source to get the stl file printed out of the correct material in an affordable range? Thanks!
I’m sorry but is anyone printing these and selling them? I am without a printer and really want one of these.
Hi Jim-
Shoot me an email – aaron@fourpointo.com
Hello Jervin I was wondering if you sell the shroud for the 7480 miter saw
I don’t sell anything (other than custom furniture). I have only designed this dust system as it is the saw I have.
I bought a Creality Neo 3 Max with a 300×300 table, and the dust collector firs diagonal as you recommended. On my first try at the print, the first layer was too skinny and the interior pieces started printing in thin air. I use Cura as well. I viewed the slices and the interior parts start between the 25th and 30th layer. What settings did you use to get the thicker top? That is really a sweet design!
I have printed this at least six times now. I typically do four starting layers. As to your first layer adhesion. Welcome to the world of 3D printing. Once you get the printer working fine, you should be okay. Work on test prints until you are familiar with the printer AND it is dialed in.
What percent infill do you use?
I have printed it at 20% and been happy as long as I used 4 outer layers.
Wow, I just completed the project. Over 90 hour print time, but it is beautiful, and heavy duty. Thank you so much for sharing your design! Maybe now, I will be able to catch the sawdust that has been eluding capture! Now to clean it up and mount it…..
Jim
Do you make parts to sell? Looking for the dewalt 718 dust collection custom adapter…
Thank
Phil
irhoodlum@hotmail.com
I am just a retired dude. Not a commercial part printer. Is the 718 similar to the one I made the part for?
Quick question retired dude…. (no offense intended sir). I am printing each side individually and will make a note to ensure I have 4 outer layers (a very good point by the way). My question is, I will be printing each half individually and would like to know if you glued them together before mounting them to the saw? I am a tech guy in a school district and have access to CAD software. I could revamp the design slightly and add pins at the inside edges to accomodate connection. I just didn’t want to do this without your permission first.
Forget my last, dumb idea because I need the kerf space……
if anyone wants one of these printed I would be happy to do the job, let me know.
If this is OK with the creator of course.
I have multiple industrial printers.. Thank you.