DeWALT Planer DW735 dust modifications from print to fully installed

[@byromscustomwoodworks]

Great video, already got the part printed but this really helps with cutting the hole for the port.

[@builderdads]

Thank you for the feedback and purchasing the part to print.

[@rollandbrower7827]

Noticed on your site it indicates it can’t be used with a shop vac, for those of us yet without dust collector can you tell us why it won’t work?

[@byromscustomwoodworks]

@@rollandbrower7827 shop vacs don’t pull a large enough volume of air and going from 4” to 2.5” will reduce it even more

[@builderdads]

@Rolland Brower to be honest that was a blanket statement made based on my assumption of the volume of air that needed to be moved. Since the question was posed though I did a rough setup to hook up my Rigid 6.5 peak HP shop vacuum to it and was surprised at the results. It did a very nice job sucking up the chips from a small 6" x 12" board of walnut that I have been using as a test scrap. I removed 0.02 of an inch and it sucked up at least 90% of the chips. Now will it work with all shop vacuums? Maybe, but it seems to work nicely with this Rigid. If you would like you can fill out the contact form on our website builderdads.com/contact and I can give you a call.

[@rollandbrower7827]

Thanks to Byron and BuilderDads for the info and help. It’s good to get the back story on using the rigid shop vac. The comments help in deciding whether or not to make the update either before I get a dust collector or before. It’s appreciated

[@3Beehivesto300]

The fan still sucks air and can be used to help cool the thermo coupler. Drill some holes in the side of the housing near the thermo coupler. Then on the inside with the cover off. The motor fan will pull air through the switch housing and help keep it cool. A flaw in the design that nobody is talking about. I piped in a 1” hose to pull air. I make bee boxes and work with wide boards.

[@builderdads]

That is a good idea. With the fan still on and just the port cover adapter covering it the air flow is pretty strong. I have yet to overheat the unit, but I wonder if some additional breather holes would improve things. Thanks for the idea. Would love to see a picture of your modification.

[@jimsharp6978]

Hi, I enjoyed your video. Do you have the upright dust hood collector in stock & do you happen to also have the Dust Right Adapter/Handle for sale also?

[@builderdads]

Glad you enjoyed the video. Yes, I currently have the modification in stock and I purchased the dust right adapter from Rockler.

[@ibuyufo]

I have a question. Why couldn't you print a 90 degree or some type of 90 degree tube and attach it to the exhaust?

[@builderdads]

Do you mean instead of modifying to go from direct off the head to using a 90° off the back stock port? If the answer is yes then the reason is that I upgraded to a Shelix head which overloads the rear impeller. I get less suction so more chips on the floor and an overheated motor that trips my circuit breaker by keeping it stock. By switching up to collecting right above the cutter the chips do not have to pass through the rear port and do not then overwork the motor. This enables my motor to run cooler without over heating . It also gives me better collection which leaves almost no chips behind. I hope that answers the question and if not let me know.

[@ibuyufo]

@@builderdads Thanks! Yes this did answer my question and I can see from your explanation that it was necessary to do it the way you did.

[@builderdads]

@@ibuyufo awesome!

[@AlexanderSchrepfer]

I always start in reverse when cutting plastic.

[@builderdads]

I didn’t oops. I had to learn the hard way that the best way is backwards.

[@adamthewoodworker2571]

Hi. Are you intending on selling this dust collector piece at some point? I know you sell the plans for it but I don't do 3d printing

[@builderdads]

Hi Adam, yes we sell them fully printed now and have inventory ready to be shipped. Here is a link to the item in our store builderdads.com/store-XqrbB/p/dewalt-dw735-planer-dust-upgrade

[@adamthewoodworker2571]

@@builderdads awesome! And this link you sent me is for your version 3 right? Also, are you planning a version 4 at some point or are you thinking this is it?

[@builderdads]

@@adamthewoodworker2571 yes the link is for version 3 and there are no current plans for a version 4.

[@adamthewoodworker2571]

@@builderdads thanks very much. I wonder, has anyone shown you a better way to cut the hole at the top yet lol?

[@builderdads]

@@adamthewoodworker2571 yes Byrom’s Custom Woodworks ran the hole saw in reverse to eliminate grabbing. As a result an update is included in the document that accompanies the physical and digital product. Here is a clip of BJ cutting in reverse. instagram.com/reel/Co7M0SnjX3C/?igshid=YmMyMTA2M2Y= He made it look easy.

[@3Beehivesto300]

You want to blow peoples mind? Find a way to put a larger motor on it. Maybe a 240v…

[@builderdads]

That would for sure be a unique modification.

[@3Beehivesto300]

@@builderdads I have an older dw735 that I bought for back up to my new one. I’m thinking about pulling the older motor and trying to mount it to the fan shaft with a coupler. Two motors inline…

[@builderdads]

@@3Beehivesto300 interesting idea. Makes one wonder how that will impact performance and if the changes are positive are they worth the cost of the modification. I'll be interested to hear update on this.

[@bradspring8332]

I see a huge lawsuit against you. You have bypassed the safety for when you have the cover off. That’s one. Second I see no safety from something falling into the top and right into the blades. Either an object or someone’s hand. You better not sell or ship this thing to anyone. Desalt designed this with safety features and you are promoting a dangerous product.

[@builderdads]

Thank you for your feedback and for raising concerns about safety. It’s an important topic, and safety should always be the top priority when using, maintaining, or upgrading any tool. I personally love the DW735 planer, but in its stock configuration, it had limitations-particularly after upgrading to a helical cutter head, which introduced challenges like clogging and poor performance due to increased chip load. While modifications can present new risks, it’s essential to understand that, like any woodworking equipment, the user assumes responsibility for its safe operation and maintenance. Caution should always be exercised, whether the machine is stock or modified. To address your concerns, here’s additional context about this modification: Safety Switch Override: The stock cover includes a lockout mechanism to prevent the machine from operating when the cover is removed. While this is a valuable safety feature, it’s crucial that users always follow basic safety protocols, including removing power sources during maintenance. For this modification: • If the cover is not cut, the safety bypass switch must be installed to operate the machine. • Regardless of safety switches, tools should always be unplugged during maintenance, as safety switches can fail. Dust Port Cover: The kit includes a dust port cover designed to prevent accidental contact with the impeller fan, improving safety beyond the stock configuration. Dust Boot Cover: To prevent objects or debris from entering the dust boot, the kit provides optional covers available in both friction-fit and magnetic setups. Personally, I use a magnetic cap to secure the dust boot when not connected to a dust collector. Unplugging the Machine: The instructions explicitly remind users to always unplug the planer: • When not in use • During installation or removal of modifications • When performing maintenance or adjustments This practice is critical for all woodworking machines, stock or modified, and is prominently highlighted in the kit’s documentation. User Responsibility: As with all woodworking tools and aftermarket upgrades, users assume full responsibility for safe operation. This includes following instructions, adhering to safety best practices, and exercising care when working with any tool in the shop. This upgrade was designed to address specific issues I encountered with my DW735 planer, particularly after upgrading to a helical cutter head. The stock dust collection system wasn’t sufficient for handling the increased chip load, and this modification significantly improved performance and dust collection efficiency. Safety is more than just a word-it’s a philosophy and a practice that guides everything I do as a woodworker. It’s something I hope every user takes seriously in their own shops. If you have further questions or concerns, I’m happy to discuss them. I take safety very seriously and strive to provide tools and knowledge that empower users to work responsibly and effectively in their shops.