Router sled blast shield (wood chip deflector)

This is a simple bolt on addition to my router sled design the provides a flip down shield to deflect some of the wood chips generated when using the router.  There is also an optional vacuum port for a 45mm vacuum hose.

Print settings:

Filament: PETG or PLA

Supports: None

Orientation: Use the orientation of the pieces in the build files.

Additional Materials:

1 piece of plexiglass or similar cut with whatever size shield you want.

10x m5 nuts

4x m5x12 hex socket bolts ( You may need shorter or longer bolts depending on the thickness of the plexiglass you chose )

4x m5x16 hex socket bolts ( You may need shorter or longer bolts depending on the thickness of the plexiglass you chose )

2x m5x25 hex socket holts

Assembly:

Attach the screen hinge and cart side hinge to each other using 2 m5x25 hex socket bolts and 2 m5 nuts.  Attach the cart side hinge to the router cart from the router sled.  Use the 4x m5 socket bolts in the router cart that are holding it to the linear rail bearing assembly.  See photos for correct placement.

Drill 4 5mm holes through the plexiglass using the screen attachment piece as template.  Sandwich the plexiglass between the screen hinge and screen attachment pieces and secure with 4x m5x12 hex socket bolts and nuts.

Drill 1 ~45mm hole through the plexiglass where you want to vacuum port to go.  Then drill 4 5mm holes through the plexiglass using the vacuum port outer piece as a template for the hole locations.  Sandwich the plexiglass between the vacuum port outer and inner pieces and secure with 4x m5x16 hex socket bolts and nuts.

Tighten or loosen the 2 m5x25 hinge bolts to control how easy it is to rotate the shield.

Bolt the screen on to the router sled cart using 4 hex bolts that are holding the router sled bracket to the linear bearing assembly.