Chop Saw Dust Hood #4: Plumbing To Connect The Chop Saw's Dust Port

  • Advertise with us
Blog entry by BlankMan posted 12-16-2009 06:52 AM 19524 reads 5 times favorited 4 comments Add to Favorites Watch
« Part 3: Outlet & Saw Swivel Clearance Part 4 of Chop Saw Dust Hood series Part 5: Well It's In The Home Stretch »

Well I got sidetracked restoring the Jet sander but did spend time on this while working on that in between waiting for parts. I cut out the circle for the saw swivel clearance like six times. There was really no good way to measure it and get it right the first time because like I said with the blade guard, handle, and motor, the cutout is closer to half a teardrop then a circle. So I’d put the hood in place, put the saw in place, and see where it bound or was too close and cut it bigger. Well I finally got it right and now have a 1/4” clearance from the blade guard, handle, and motor at any point from 47 degrees left to 47 degrees right.

So I moved on and installed the pipe and elbow that will allow me to connect to the dust collector port that is behind the blade on the chop saw. Delta supplies a bag with the saw that normally connects there but I’m not going to use that so I figured I’d connect a hose to it. That was a bit of a problem in and of itself because I had to find an 1-3/4” ID hose and I found out that size is not readily available. I found it at Grainger and I could use my friends account at Grainger but didn’t feel like doing that so I ordered it from To my surprise when it arrived today, it came from Grainger so must have some agreement with Grainger. Ordered it yesterday, got it today. I like that.

I also spent a lot of time sanding, due to my laziness with gluing it up. I normally use blue tape on the glue joints where the glue can squeeze out. But this time I didn’t. When I did the dry fit I scribed a line with a pencil and used the line to mark where to spread the glue. Well now that it’s all together you could see those pencil lines. Not a big deal if I where going to paint this but I’m just going to poly it. I like the look of the Baltic Birch so I don’t want to cover it with paint. Well that meant I have to remove the pencil lines. Not an easy task when they’re right in the corners.

So I tried my PC profile sander, didn’t work well and just barely could get in there. And the paper would wear through quickly and then I’d get black streaks from the rubber of the 90 degree profile attachment. So a scraper, foam sanding blocks. sandpaper and a lot of elbow grease the last two days. Oh I found some 3M foam sanding blocks that had a 15 degree bevel on the edge that made getting in the 90 a bit easier.There was also a thin layer of squeezed out glue which added to the difficulty before I could get at the pencil line. I will never do that again, scribe a pencil line, blue tape from now on, no laziness.

Oh, in order to drill the hole for the pipe into the plenum chamber I had to make a template for the hole because it enters the top at a 15 degree angle. So I used a 1-7/8” hole saw and cut a hole in a 2×8 and then cut a 15 degree bevel on it on the table saw. I then clamped it in place and used it as a guide for the hole saw with its drill bit removed.

And the other hole you see is not a mistake, that is where the plastic insert for the cord will go.

Template clamped in place.

Side view of template showing the 15 degree angle.

Side view of template showing the drill and hole saw ready to go.

Pipe installed, glued, and clamped.

-- -Curt, Milwaukee, WI

4 comments so far

View Belle City Woodworking's profile

Belle City Woodworking

357 posts in 5469 days

#1 posted 12-16-2009 06:59 PM

Looking good Curt!

-- Formerly known as John's Woodshop - and NO not the one from Ohio!

View blockhead's profile


1475 posts in 4760 days

#2 posted 12-17-2009 03:50 PM

That is coming along really nicely.

-- Brad, Oregon- The things that come to those who wait, may be the things left by those who got there first.

View sIKE's profile


1271 posts in 5206 days

#3 posted 12-31-2009 05:57 PM

Did you have to purchase a 12ft section of that hose?

-- //FC - Round Rock, TX - "Experience is what you get just after you need it"

View Elizabeth's profile


823 posts in 4596 days

#4 posted 10-18-2012 05:55 PM

I’ve got a similar problem trying to find hose to replace my Dewalt Miter saw’s dust bag. Can you tell me what item you ended up ordering from It won’t be the exact item I need since Dewalt uses a 1.5” ID port but it’ll get me pointed in the right direction.

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics