Dewalt DW735 Dust & Chip Collection

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

1. Print the angled inlet and straight exhaust port out of PETG.
2. Place the 2 prints on the lid of your Rubbermaid and mark the screw holes on the lid.
3. Use a 5/32" drill to make all 8 screw holes through the lid.
4. 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).
5. 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).
6. Permanently secure the prints to the lid. Use flat washers on both sides.
7. 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.
8. 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.
9. 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.
10. 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.
11. Enjoy your thickness planer!