Dewalt DW735 Dust & Chip Collection
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Capture sawdust and chips from your Dewalt DW735 thickness planer in a 20 gal. Rubbermaid Roughneck refuse bin.
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Model information
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- Printables
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- Tools
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Description
The Dewalt DW735 generates such a heavy chipload that the manual recommends it NOT be hooked to a ShopVac. This set of models lets you convert a 20 gal. Rubbermaid Roughneck refuse container into a chip and dust holder.
Parts Required
You will need the following hardware to build this chip storage bin:
- A Rubbermaid Roughneck 20 gal. refuse bin
- 8x M5 machine screws (your choice of length, I did 25mm)
- 8x M5 machine screw nuts
- 16x M5 flat washers
- 3x 4" hose clamps (with worm screw to tighten)
- 6' of 4" flexible hose (found in the HVAC aisle)
- Cold air return filter media (optional)
- Hot glue gun
Print Instructions
The assembly in the pictures was printed at the following settings:
- Printer: Prusa i3 MK3S & Prusa Mini+
- Print Settings
- 0.6mm nozzle
- 6 perimeters
- 20% infill
- Filament: generic yellow PETG
- Supports: none
- Brim: none
PRINTING NOTE 1: I suggest increasing the # of perimeters until the 4" inlets print solid without infill. You'll be tightening a hose clamp on these and don't want them to break.
Assembly Instructions
- Print the angled inlet and straight exhaust port out of PETG.
- Place the 2 prints on the lid of your Rubbermaid and mark the screw holes on the lid.
- Use a 5/32" drill to make all 8 screw holes through the lid.
- Temporarily secure the prints on the lid using some screws. Trace the inner 4" hole of each print onto the lid with a pencil (one round, one oval).
- Remove the prints from the lid. Drill a ¼" hole in the middle of your tracing, drop a handsaw through it, and cut out the large hole in the middle of each print (one round hole, one oval).
- Permanently secure the prints to the lid. Use flat washers on both sides.
- There will be gaps between the print and the lid. We don't want sawdust shooting out! Use a hot glue gun to run a bead of glue all the way around, sealing the prints to the lid.
- Cover the exhaust port with a filter of some sort. I used a cut-up piece of air filter meant to go in a cold air return. I imagine a thin t-shirt would work as well. Secure the filter media to the exhaust port with a 4" hose clamp.
- Hook the chip inlet to your DW735 using the flexible hose. Be careful not to tear it. Try to keep it somewhat taut so that chips don't get stuck.
- Use the little clips to keep the lid secured to the pail otherwise the high air pressure will lift the lid right off the bucket.
- Enjoy your thickness planer!