Dewalt Sliding Miter Saw Dust Collection

[@camarols6]

Woodworking AND 3d printing. Im in heaven!!! Great thinking and design!

[@bradvirgil1255]

Great Video. With my son's help on 3d printing, we were able to implement your plans. It worked great and much better dust collection going to my 2 hp system. Dewalt ought to make it and they would definitely sell more of their miter saws.

[@Blueridgedog]

Thanks. I think I am on my fourth one (they get chopped up over time) and I still prefer it to the original by far.

[@sambaaam7268]

this is the best miter saw dust collection I have seen and I have looked at a lot, thanks for sharing

[@markkoons7488]

The insights made evident seem useful to those of us who will only cobble materials together. Thank you.

[@johnlysic6727]

Very interesting - I really like the finished version - thanks for sharing

[@mikehall4472]

This is some great engineering - thanks for sharing. Sadly, my printer isn't big enough for the design. But you gave me some inspiration. I was trying to work out how to avoid reducing the bore of the ductwork from my extractor (100mm) using your design, and realised the duct will fit behind the blade if cut. I laid a 100mm flexible duct across the back of the saw with one end blocked. I then cut a section out of the pipe which was in line with the dust exhaust, and big enough to take the saw body when cutting at full depth. It captures nearly everything and you can slide it back and forth to accommodate mitres. Cheap and easy, but I couldn't see the wood for the dust until you shared your design! Thanks

[@Blueridgedog]

Excellent. Love to see a picture of it.

[@kevinchandler5424]

I have the same saw! Any chance you would make another one and sell it to me??? I’ve been fighting the dust collection for a few years now and just can’t seem to find the right solution. Your design etc looks perfect!

[@LemonySnicket-EUC]

He supplied a link to the file. If he doesn't want to make one for you then get the file and find someone with a 3d printer and have them make it for you.

[@michael.schuler]

Well conceived hood for most shop work. I'm a finish carpenter and need to regularly make use of the saw's entire range of both miter and bevel cuts to deal with jobsite conditions. Am I correct to conclude that this dust hood would fairly quickly be destroyed by miter cuts other than at 90 and 45, as well as by bevel and/or compound angle cuts?

[@superphilschneider]

Hey James, nice job. I wonder if you could have used a sacrificial top plate that could be replaced, once you've done a number of angled cuts. Did you use a dust collector or a shop vac for the air movement? Dust collector needs to minimise any "minor losses" due to fittings, etc, so might be an even better idea to not reduce down to the 2 1/2 " port sizes. Overall, though, I like your process and feel like you've created a nice, minimalist solution.

[@deemsdavis7811]

James, Thanks for your work on this, it was timely for me as I was in the midst of setting up a new shop in new home. After getting quotes to have a 3D service print it for me, I bought my own printer and printed your part as well as a 3 way manifold to tie into 6" duct. ( saved $ vs the costs of the services) I've been noodling about some improvements ( a replaceable sacrificial top, some way to allow for the saw base to rotate without creating a new saw kerf in the top, and how to incorporate a collection point that replaces the old "following" tube and "connects with the bottom back of the saw guard." I enjoy tinkering with CAD when I have the time.

[@rudboy11]

I am thinking of doing the same thing. Mind if I ask what printer you went and what bed size do you recommend?

[@Blueridgedog]

I would be curious what you come up with. I too have tried designing some of those changes, but not hit upon a good outcome. So far I am still happy with the function, but it could be better, but IMHO it is still an improvement.

[@michael.schuler]

Have you taken on the challenge of CSMS dust collection that allows for the saw's full range of compound miter cuts, including all bevel angles. I admire the elegance of the work here, but as a professional finish carpenter, abridging the saw's full functionality make this solution, with all its merit, inadequate. I am working to solve the problem I pose and have tentatively concluded that the solution cannot rely solely on hard components, but rather must incorporate flexible ones of rubber, and/or a much bulkier shroud not intended to capture dust straight from the blade. Yet I hope to avoid the big tents used in the Rousseau and Fastcap commercial designs. Any thoughts?

[@josephromonsky6154]

are you selling these would like to buy the dust collection for dewalt

[@travisradke9753]

If you decide to make and sell these, put me down for one for sure. Great design!

[@rflournoy]

I like what you've done. I'm going to take your .stl and try to make a minor mod so it will fit my Ridgid miter saw. Thank you!

[@robertjames-life4768]

I made the same sort of thing out of wood except I took the upper fence off and and incorporated the collector and a zero clearance fence that is held in with the threaded nuts, really easy to remove. I didn’t worry about angled cuts as 90% of what I do is 90 degree cuts.

[@meadvino]

robert do you have a picture or other details about your design? i like the idea of making something out of wood and not needing a 3d printer

[@markpierce823]

Factual, intelligent and not a bunch of flash just the way I like videos even though I do not have a dewalt.

[@ko6128]

Boy I’d be trying to sell those designs to the various miter saw mfgs. Festool could sell them for $5000.

[@mshideler]

Did you remove the rear guard on the back side of the blade to fit the dust collector? The part is also called dust deflector or ““SA REAR GUARD AND DEFLECTOR SERVICE”. The same piece recalled earlier this year.

[@Blueridgedog]

I "think" so. I had to remove the entire original dust collection assembly.

[@mshideler]

Thanks!!

[@chriss8206]

Please make me one I love it. Should be on the market.

[@GarageGeek]

Wow, thank you for sharing.

[@jimw6991]

Hi James, when you are cutting width or thick pieces, I think you will find dust isn't being captured. If you come up with a way to keep port close to blade when it is slid out then you will have solved this riddle. I have a compound sliding miter and built a hood . I have sliding doors (curtains) on each side of blade as well as a plenum beneath the saw to allow dust pickup in three locations. In rear on each side of overarm post and beneath blade. Getting about 95 percent.

[@Blueridgedog]

Yea, anything 6" or above needs a modified solution. Most of my cuts fall under that so I have not been driven to innovate it much further, but will when time permits.

[@HeyMichaelLeo]

So what happens when you need a 22.5° cut, can the unit handle another cut?

[@mrJajasper]

Thanks for the file, as I am looking at having this printed, what measurements were the file in?

[@Blueridgedog]

It has been a long time since making the file. I think the default export is MM. It should take up most of a 300 mm bed.

[@DuongNguyen-gg3uc]

Hello @James Ervin; Where can I get the dust collection? Thanks,

[@johnkeith5341]

Which DeWalt saw did you make this for? I have the DWS779.

[@AkinetikFitness]

This is amazing!

[@nicholaswoods9788]

i was about to get a new saw but this might just save the dewalt :)

[@jeffreywhite-th8wp]

I can not afford a printer how much would you charge to make one

[@bwelles5983]

I would sure like to buy one!!

[@dennisfisher8857]

You might want to talk to Fastcap for the production of this. I think this would sell a lot.

[@carterscustomrods]

Has anyone discovered a good resource to have one of these made?

[@HemiDad1963]

That’s very nice. Thank you for sharing.

[@jayevans9142]

How much is the one for the single hose I would buy that I am going crazy trying to figure this out. I will never get rid of my dewalt saw far as I am concerned it's the best saw on the market. Does the single still make 45s both ways

[@michaelsolano8733]

Excellent work!

[@meadvino]

BTW you can get this printed by a 3d printing service for about $40, which includes shipping. pretty reasonable

[@ronaldhaynes9003]

That's not only a great, new idea for dust collection on the DeWalt sliding mitre saw, that's a darn nice looking cabinet you have it mounted on! Will you ever feature the cabinet and your shop? Thanks!

[@Blueridgedog]

I don't have a video on it, but you can see the build here: www.theraven.us/index.php/2018/02/05/miter-table-bench/

[@ronaldhaynes9003]

@@Blueridgedog Just went there...you REALLY know what you're doing! Thanks!

[@bartela]

Is it normal, that every time start this saw from dead stop it throws up head??? Or it is some problem with something??

[@Blueridgedog]

The centripetal force of the starting blade wants to push the head "up". I have gotten into the habit of starting it up, or just being prepared for the upward push.

[@bartela]

@@Blueridgedog right, thank You for info

[@sillydg]

Nice job! Would you be willing to make one for sale? I'd be interested.

[@kevinjackson5191]

Excellent video thanks. How do you combat dust when you bevel the saw?

[@Blueridgedog]

It works great for angled cuts, it just puts another cut in the dust shroud. Eventually a pie shaped area will be removed. Beveled cuts have a similar impact in that the area from 90 degrees to 45 degrees gets chewed up. I have printed a second after using the first for some time. I do furniture exclusively, so I don't make may beveled or angled cuts.

[@kevinjackson5191]

@@Blueridgedog thanks for the reply. I’ve had my 717 for a good few years now and have just bought my first 3d printer. So.....this is what I’ll be trying. Have you done anything with the dust port behind the saw head?

[@Blueridgedog]

@@kevinjackson5191 In order to put the saw as close to the wall as I could, I had to remove the included dust collection. If your printer lacks the size the print it all at once, your slicer software (the software you use to make a printable file from a shape file) can split it in two.

[@lschratzmeier537]

I have no source to use a printer like that. Do you make and sell them?

[@jimporter47]

James, I would like to purchase one as well. How can we contact you?

[@philippeterson9512]

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.

[@Blueridgedog]

Outer edge is 130mm

[@philippeterson9512]

Thanks!

[@zestboy1]

James would you be willing to make and sell your double inlet dust collection for the dewalt miter saw? great design!

[@Blueridgedog]

My printing capacity is limited, as my 3d printer is basically scrap. I am looking at the cost of getting it injection molded, so folks can have it easier.

[@chrisdavis1482]

Is your saw the Dewalt model DWS779? I may have access to a 3D printer and would like to make one of these for mine but want to make sure it's the same model first. Thanks!

[@Blueridgedog]

Mine is the DWS779.

[@waynemeriwether1739]

I wonder if it would also fit a DWS780?

[@Renrondog]

@@waynemeriwether1739 Yes, they are basically the same saw

[@199tigertail]

I just got a quote from a local printshop and they wasted $300. Is that accurate?

[@Blueridgedog]

That is stunningly high. It is about half a roll of filament (so $15) and 24 hours on a machine.

[@biggdogg35810]

James, would you be interested in making one for a Ryobi 10” sliding compound miter saw and selling it?

[@Blueridgedog]

I would be glad to design one that can be printed, but I don't have the saw to measure and test on. Like this one, when finished, I would just make the file available for print. I can't print them or have them produced at an affordable price.

[@meadvino]

can you post the STL file for the 2 1/2" x 4" hose adapter on your site please???

[@Blueridgedog]

I have not posted that one as you can buy it from rocker for $12. If you still want it, contact me directly and I will find it.

[@meadvino]

@@Blueridgedog thanks. i see that rockler & woodcraft sell them.

[@keithkuckler2551]

You should sell these, or sell the patent to De Walt. But, i have to ask, when you cut a 45 from both sides the piece in the middle must just drop out, and, that must allow for some loss of effiency.

[@Benchmark1033]

Do you know what model DeWalt Miter saws this works on?

[@Blueridgedog]

It should fit any 12" sliding compound miter they make, but mine is the DWS779.

[@TheBorderReiver]

What 3d printer do you have that will print this large of a design?

[@Blueridgedog]

My old TAZ5 prints it, my new Voron 300 will too. For smaller printers, just use the slicer to split it, then glue it back together after printing each half.

[@louis90112]

This is the best

[@mshideler]

What infill % did you use to make the dust collector?

[@Blueridgedog]

I have done 40% a few times and 60% once.

[@stevesiefken6432]

How much sawdust comes out the front? I am experimenting with a couple solutions that work well for the back. Thanks!

[@Blueridgedog]

I get little out the front, and little out the back on boards 6" or less. Wider boards throw some past the device and would benefit from a taller shield.

[@feds27]

You probably need to account for the dust being ejected into the area below the zero clearance plate. :-)

[@thedodsons38]

Can I make this work with just a shop vac?

[@jeffw8611]

To some degree, it may. A shop vac moves a small amount of air at high pressure while a dust collection unit moves large amounts at low pressure. You'd need the high CFM for the multiple intakes and wye to really work well. If the vac was right at the saw your results may be satisfactory.

[@JavierLopez-jp4ur]

Donde puedo comprar uno

[@WiedemannPhotography]

Curious what 3D priniter you used for this build?

[@Blueridgedog]

A very old LuzBot...TAZ5

[@WiedemannPhotography]

@@Blueridgedog thanks for the reply. I am looking at getting in 3d printers and noticed the one you were using looked like it had a bigger plate.

[@Blueridgedog]

@@WiedemannPhotography Oddly enough that is the sole reason I keep "rebuilding" it. It was junked at my workplace and you can't find that size easily, so I have just kept it going.

[@WiedemannPhotography]

@@Blueridgedog I haven't looked at your file yet, but do you have any recommendations on an affordable printer that works with the dimensions. Thanks again for your comments and sharing your design.

[@Blueridgedog]

@@WiedemannPhotography This is pitched as "your second printer" in that it is a bit more advanced, but IMHO is the best thing out there right now: seckit3dp.design/price/sk-go

[@Jonnay0808]

What did you do to secure the shroud to the saw?

[@Blueridgedog]

Construction adhesive.

[@hastyman]

How does it do with bevel cuts?

[@Blueridgedog]

I can't say...I only make furniture and have never tilted the saw in its life. It should be the same as it simply get a slot cut in the top and the top is more or less sacrificial.

[@hastyman]

@@Blueridgedog Thanks for the reply. I'm pretty sure I have the same model saw as you. It's a nice saw, but messy. I frequently find myself doing both miters and bevels at various settings so I'm thinking that top would be short lived in my shop... but I'm intrigued at the concept. I don't own a 3d printer but maybe I can cobble up something effective the old fashioned way.

[@Blueridgedog]

@@hastyman The saw certainly needs help with dust collection, so anything you try is likely to improve it. I am thinking through an attachment that goes out with the blade as well.

[@Mike--K]

@@Blueridgedog James, you are a genius! I've been debating on getting rid of my DWS780 and buying a Kapex 120 because of the dust. If you make the top of the shroud replaceable, like zero clearance inserts, then this sacrificial part can be easily replaced when needed.

[@Blueridgedog]

@@Mike--K Well, it works great thus far, especially for 5" or shorter. I still make a mess when I put on a big slab of wood. Working on another version that may help, but for now the worst part is addressed.

[@Doublethizzle]

1:05 Definitely not a DIY video. I'm sure it works well (didn't make it past 1.06) it's above my pay grade

[@Blueridgedog]

If you are not into the current 3d printing trend or open to having an item printed by a friend then yea, the end result will do you no good.

[@thomasclemens1386]

I made one of these. I was underwhelmed about how well it worked. Plus I had to take off the metal bracket on the daw that is attached to the dust boot in order to allow the blade to lower enough to make a thru cut. Everyone who does things like this says 95% of my cut are cross cuts…. True but for the other 5% you have to take the whole thing off….. and then have NO dust collection. Save time and energy. Get a Roseau 5000. It’s not perfect either but when hooked up to a vac it gets at least as much as this thing plus you never have to take it off and haven’t reduced the functionality of the saw. To his credit He never claimed it was perfect. But really why have a mitre saw if you can’t mitre???

[@nycboxing8359]

Dude named his black dog jango 🤣🤣🤣🤣 You made this video to make us fall in love with something we can’t have 🤔🤔🤔🤔 Shame on you send off to have it duplicated and please sell them🙏

[@Blueridgedog]

Probably my favorite Tarantino character! The pup certainly has grown into the name. He is loyal to a fault and has not an ounce of fear in him.

[@woodbutcherjc]

What dust cyclone are you using?

[@Blueridgedog]

It is an older one from Penn State Industries, but I don't think they make them anymore.