DeWalt 735 Thickness Planer Dust Port Replacement

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Project by tyvekboy posted 06-17-2014 09:07 PM 5034 views 10 times favorited 16 comments Add to Favorites Watch

June 17, 2014

You may not have a DW-735 Thickness Planer yet but you may so this post may be something to keep in the back of your mind.

Eventually you will break the 4 inch dust port supplied with this great tool.

When this happens, what are you to do? I’m very frugal. A new replacement part may just break again. So this is what I did.

I laminated 3 pieces of 3/4 inch plywood together and sized it to fit both the machine side of the port ….

… as well as the hose side of the port.

This new one fits and snaps and clicks in place just like the original plastic one. It is also heavy duty!

The only problem you’ll discover is that the release button is going to be hard to get to and is going to require a tool.

The tool I made consists of a stiff piece of wire that will fit in the hole with a wooden knob on the end.

The tool fits in the little hole and is used to depress the spring-loaded button so that the adaptor can be rotated and removed.

NOTE: Making the tool is not necessary as pointed out by DGar in comments below. Also note that MT_Stringer suggested I paint the wooden adapter BLACK …. it does look better. Thanks for the suggestions both.

You can either fit a 4 inch hose over the end to connect to your dust collection system or you can put a 4 inch Dust Right adaptor on it.

OR …. you can do what I did in my next post.

BTW …. This wooden adaptor was accidentally broken when I had the outfeed table in the UP position and my son was lowering the head and didn’t realize that the outfeed table had to be lowered before the head was lowered. A little titebond glue and when the glue set up it worked fine. Couldn’t have done that with the plastic affair.

Comments encourage and questions welcomed.

Thanks for looking and I hope this helps all the owners and owners-to-be with a common problem.

-- Tyvekboy -- Marietta, GA ………….. one can never be too organized

16 comments so far

View Dan Lyke's profile

Dan Lyke

1520 posts in 4573 days

#1 posted 06-17-2014 09:10 PM

Oh excellent! I went down to the local hardware store and found a piece of plastic pipe that’s just a little bit too big, barely catches the pins, and layered duct tape on the inside to make it stay centered so it’d stay on. I think I’ll have to laminate up some ApplePly to make this happen!

-- Dan Lyke, Petaluma California,

View HillbillyShooter's profile


5811 posts in 2741 days

#2 posted 06-17-2014 09:21 PM

Very clever solution to what appears to be an engineering weakness. Congratulations on your ingenuity!

-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington

View MT_Stringer's profile


3183 posts in 3679 days

#3 posted 06-17-2014 09:34 PM

Looks good. A little professional black paint and you will be good to go. :-)

-- Handcrafted by Mike Henderson - Channelview, Texas

View English's profile


677 posts in 1925 days

#4 posted 06-17-2014 10:53 PM

Good Idea, Thanks for sharing

-- John, Suffolk Virgina

View Roger's profile


21007 posts in 3252 days

#5 posted 06-17-2014 10:54 PM

+1 on what John C said

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. [email protected]

View Jim Jakosh's profile

Jim Jakosh

22995 posts in 3554 days

#6 posted 06-17-2014 11:14 PM

ARR ARR ARR as Tim the Toolman would say…...Great solution. Wood replacement parts will out live the plastic thin walled stuff a long time…........Nice gong!!......Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View Schwieb's profile


1890 posts in 3910 days

#7 posted 06-18-2014 02:43 AM

Nice work Alex. Ingenuity wins over poor engineering.

-- Dr. Ken, Florida - Durch harte arbeit werden Träume wahr.

View ChuckC's profile


843 posts in 3383 days

#8 posted 06-18-2014 03:31 AM

Love it. I broke mine in the very same way.

View stefang's profile


16711 posts in 3782 days

#9 posted 06-18-2014 06:57 AM

Great solution. I don’t have a DW planer, but I have made quite a few similar dust ports for various tools and they are very handy.

-- Mike, an American living in Norway.

View DGar's profile


40 posts in 2302 days

#10 posted 06-18-2014 12:46 PM

Great solution! I’ll keep this in mind when mine eventually breaks. For what it’s worth, I use the included hex/star tool to release the button on the dust port. Not sure if that would work with your solution.

-- "Those who are not dissatisfied will never make any progress" - Dr. Shigeo Shingo

View bobber52's profile


2 posts in 3443 days

#11 posted 06-18-2014 07:10 PM

That’s a great idea Alex.! I’m going down to the shop now and look at putting your ideas to work. Thanks for sharing.

-- Bob, Burnsville, NC

View tyvekboy's profile


1917 posts in 3461 days

#12 posted 06-18-2014 11:38 PM

Just wanted to thank all who left comments and favorited this project.

MT_Stringer – Took your suggestion and painted the wooden adaptor BLACK. Must admit it looks better.

DGar – duh-h-h. You are right. The blade changing tool that’s included with planer DOES indeed work to push the spring-loaded button.

-- Tyvekboy -- Marietta, GA ………….. one can never be too organized

View NormG's profile


6439 posts in 3452 days

#13 posted 06-19-2014 01:09 AM

Great idea and if need be you can make another

-- Norman - I never never make a mistake, I just change the design.

View luv2learn's profile


2955 posts in 2751 days

#14 posted 06-22-2014 11:30 PM

What a great economical solution. Thanks for posting.

-- Lee - Northern idaho~"If the women don't find you handsome, at least they ought to find you handy"~ Red Green

View LeeCig's profile


5 posts in 442 days

#15 posted 06-02-2018 02:34 AM

Loving the dust collection ideas.

showing 1 through 15 of 16 comments

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