Dust Collection on Dewalt Saw

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.

Author: jervin

13 thoughts on “Dust Collection on Dewalt Saw

  1. 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.

    1. 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.

        1. 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.

  2. Looks awesome! Really like it. Makes me wish I had 3D printer.
    Do you sell them? If so how much?

    1. 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.

  3. 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.

  4. This is amazing, James. Very solid work. Working with a friend to get one printed. I’ll let you know how it works!

    1. 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).

  5. 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?

    1. 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.

  6. 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?

    1. 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.

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