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Dewalt Miter Saw Dust Collection

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Blog entry by BlueRidgeDog posted 02-06-2020 12:49 AM 793 reads 2 times favorited 19 comments Add to Favorites Watch

So I have the same miter saw as a lot of folks, the Dewalt DWS779. It shares a frame with several models.

The dust collection on it is poor to horrible. Mine is zero as I had to remove the stock dust collector as the rail extends far enough back as is and to mount it to a normal cabinet you have to remove it or have nearly no room for the wood you are cutting.

I designed one that would allow me to make use of my 4” dust collection system:

I needed an adapter to go from one 4” to two 2.5” hoses:

It took five prototypes, but eventually things came together. The final challenge was keeping the saw’s ability to turn 45 degrees.

It is shockingly effective:

https://youtu.be/gqgEqUNM8Is



19 comments so far

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BlueRidgeDog

629 posts in 411 days


#1 posted 02-06-2020 12:52 AM

<iframe src=”https://www.youtube.com/embed/gqgEqUNM8Is” frameborder=”0” height=”315” width=”560”></iframe>

Apparently I have no idea how to embed video on this site.

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LittleBlackDuck

3670 posts in 1452 days


#2 posted 02-06-2020 08:11 AM

Hmmm, Is it a secret or patent pending? How designed… printed/fabricated! A few more details would be appreciated. This certainly raises my curiosity as I can see useful applications of 3D printing and laser engraving/cutting in a workshop.

-- If your first cut is too short... Take the second cut from the longer end... LBD

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Redoak49

4404 posts in 2620 days


#3 posted 02-06-2020 11:40 AM

Great job….and seems to work well.

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BlueRidgeDog

629 posts in 411 days


#4 posted 02-06-2020 12:06 PM

Not secret. I will have a longer post or update on the design and fabrication. In short it is designed in Fusion 360 (though the first two versions were designed in SketchUp). It is simply printed on a 3d printer. I had to print it several times, some due to failures of such a large print and others due to design changes. When I get it to final (I think I have one more tweak) I will put the STL file up. The 4 inch to dual 2.5 inch adapter alone will be useful.

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pintodeluxe

6063 posts in 3445 days


#5 posted 02-06-2020 06:43 PM

Very ingenious solution. Quite clever indeed.
Looks like the collection is very good.

Are you worried that as you make odd angle cuts, it will basically remove the top of the shroud?

I made a ZCI for my miter saw but after a couple months use it wasn’t zero clearance anymore because bevel cuts remove part of the insert.

For dust collection I re-purposed a flexible tent frame and made a fabric hood. It works good for containing the dust, but I wouldn’t say extraction is excellent though.

Nice job building this. Thanks for posting the cool idea.

-- Willie, Washington "If You Choose Not To Decide, You Still Have Made a Choice" - Rush

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LittleBlackDuck

3670 posts in 1452 days


#6 posted 02-06-2020 11:15 PM


Not secret. I will have a longer post or update on the design and fabrication…. design changes…
- BlueRidgeDog

I made a ZCI for my miter saw but after a couple months use it wasn t zero clearance anymore because bevel cuts remove part of the insert.
- pintodeluxe


Just a thought…
I’m fairly sure the top face (with the “kerf”) is not a ZCI but a clearance slot, and could be destroyed with a wrong ° setting. What about some sort of circular insert that could be rotated (51° in diagram) to follow the mitre °,

naturally not to scale and the diameter/dimensions of the top insert will need to be adjusted to kerf and setup physics. Would also need to work on a hold down mechanism… tabs on top rim of base.

-- If your first cut is too short... Take the second cut from the longer end... LBD

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sansoo22

625 posts in 286 days


#7 posted 02-06-2020 11:27 PM

LBD I think you’re almost there. Just need some positive stops that match the stops on the saw bed and a quick release pin so you can turn the plate and lock it back in quickly. Should be easy enough for you to build in your NASA labratory.

BlueRidge this might be the best shroud ive seen for this saw. I own the DWS780 which is pretty much the same thing from what i can tell. Its stock dust collection is atrocious at best. I keep watching your vid and wondering where all the dust goes.

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pintodeluxe

6063 posts in 3445 days


#8 posted 02-07-2020 04:47 AM


Just a thought…
I m fairly sure the top face (with the “kerf”) is not a ZCI but a clearance slot, and could be destroyed with a wrong ° setting. What about some sort of circular insert that could be rotated (51° in diagram) to follow the mitre °,

naturally not to scale and the diameter/dimensions of the top insert will need to be adjusted to kerf and setup physics. Would also need to work on a hold down mechanism… tabs on top rim of base.

- LittleBlackDuck

I wasn’t implying that it’s a ZCI. Just that it’s similar in that it will get chewed up once you make bevel or odd angle cuts.

-- Willie, Washington "If You Choose Not To Decide, You Still Have Made a Choice" - Rush

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LittleBlackDuck

3670 posts in 1452 days


#9 posted 02-07-2020 05:20 AM



I wasn t implying that it s a ZCI…
- pintodeluxe

My poor wording pinto’... I misquote anything that has a blade pass through it as a “kerf” and hence ZCI slips incorrectly into my vocabulary.

-- If your first cut is too short... Take the second cut from the longer end... LBD

View therealSteveN's profile

therealSteveN

4858 posts in 1206 days


#10 posted 02-07-2020 05:24 AM

Watching the video it sure seems like there is a line in the top, going toward the right on what looks like a 45* miter. Nothing looking chewed up there. Now if you tried cutting 5 to 10 different miter angles, there isn’t anything that won’t get chewed up, but from the looks of it a 90, and a 45 to each direction looks like it should be doable.

BRD, Rockler is your friend. At 8 bux, you have to buy more stuff to get free shipping.

“Rockler 4” to 2.5” x 2.5

https://www.rockler.com/rockler-4-to-2-1-2-dust-collection-y-connector

Or keep it a bunch of 4” till closer to the tools, then use an adapter to take it down to 2.5” They have both 2 splits, and 3 splits.

https://www.rockler.com/3-way-dust-collection-junction

-- Think safe, be safe

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LittleBlackDuck

3670 posts in 1452 days


#11 posted 02-07-2020 06:33 AM


BRD, Rockler is your friend…
- therealSteveN
tRN, not that I’m challenging you, however, I’ve always found that what one manufacturer claims as a 2.5” (or 4”) hose just doesn’t fit another manufacturers 2.5” (or 4”) receptacle. I have a mix of about 4 different brands of shop-vacs that advertise 2.5” ducting, yet no two are compatible… and that is then transferred through the tool manufacturers. Before my 3D printer, I used mega rolls of duct tape and wasted countless hours in the search of compatibility… which when costed would cause embarrassment.

You may be lucky through collusion between American manufacturers (though all is probably made in China), the offerings here in Australia are never compatible.

-- If your first cut is too short... Take the second cut from the longer end... LBD

View BlueRidgeDog's profile

BlueRidgeDog

629 posts in 411 days


#12 posted 02-07-2020 11:49 AM


Are you worried that as you make odd angle cuts, it will basically remove the top of the shroud?
- pintodeluxe

The rear of the support goes past the blade, so at worst there will be simply a notch cut out eventually. I have tested with the notch out and there is no impact on how it works. So far I am really satisfied versus my old method of a big box on top.

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BlueRidgeDog

629 posts in 411 days


#13 posted 02-07-2020 11:51 AM



Watching the video it sure seems like there is a line in the top, going toward the right on what looks like a 45* miter. Nothing looking chewed up there.
- therealSteveN

Yea, there is an area that will get used up when cutting angles and eventually expose a 90 degree section if you cut many different angles. I rarely do anything other than cross cuts, but even when that section is gone, it seems to have no degraded performance.

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BlueRidgeDog

629 posts in 411 days


#14 posted 02-07-2020 11:53 AM



Just a thought…
I m fairly sure the top face (with the “kerf”) is not a ZCI but a clearance slot, and could be destroyed with a wrong ° setting. What about some sort of circular insert that could be rotated (51° in diagram) to follow the mitre °,- LittleBlackDuck

This is a simple replacement top if you are concerned. For me it is no issue having the top get a pie shaped opening. Given the simplicity of it, some extra top inserts could be made.

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Craftsman on the lake

3118 posts in 4069 days


#15 posted 02-08-2020 01:54 AM

I’ve got a 12” bosch sliding saw, I’ve got a 10” dewalt that I use when I need to take it someplace. Good saw. I’ve got dust collection for the bosch in the shop and it’s sort of okay. I’ve put a lot into it. vacuum, cowling, etc.

Ya know…. when I use the dewalt out and about I hang a dishtowel over the exhaust nozzle on the back of it. The dust hits it and falls to the ground directly beneath it. Oddly enough, I find that this is the best way to collect a larger part of the sawdust. I don’t know why I don’t use it in the shop.

-- The smell of wood, coffee in the cup, the wife let's me do my thing, the lake is peaceful.

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