Dewalt Mitre Saw Station
The hood and the dust collection options were
optimized for the Delta.
The height of the Delta table matches the bench extensions.
The Delta fence aligns with two extension
|Left side...there was an
extension on the left end of the Delta table.
This meant that the the saw was not centered in the workstation opening.
|Here is the setup with the Delta removed...|
|The old Delta was removed from
service due to a dust shroud decomposition.
It was then determined that this Delta miter saw model was discontinued...no there were no parts available.
The motor had been sounding badly during the breaking process... and it was time for new saw.
New Miter Saw
Double-Bevel, Compound, 12-Inch, 15-Amp
|The Dewalt mitre saw has a
dust port that is designed to capture dust in
a "dust bag" .
The hose from the Festool CT22 hose fits perfectly into this port.
|However, there was immediately a problem...the dust hood on the Dewalt feeds straight out the back and once it is coupled with Festool hose it runs out of room rapidly.|
|There is plenty of room to move the saw forward but even when it is all the way toward the back the fence of the saw sits out proud of the extension fences by an inch +|
|The new saw sits roughly one inch
below the bench extensions.
For the CTD stage, I supported the unit with a 1 x 2 x 3 blocks.
|And then checked the height of
the table...it was 1/32 lower than the benchtop.
Remove everything (hood, saw platform) and start from scratch to fix these issues.
|Pulled out the old hood...
|Work surface and hood supports exposed...|
|The rectangular dust port at the
rear was rigged...screwed to the rear of the work surface plate
and to a scabbed ledge on the rear bench support.
|...pulled it...size is 3.5 inches by 10 inches with 1 inch flanges|
|Area with all work surface
supports pulled and most of the hood bracing removed.
From front bench supports to the rear support is 27 inches.
Front to the wall studs is 28.5 inches.
From side support to side support is 28.25 inches.
New work surface plate will need to be 3.5 inches below bench surfaces.
The saw table height is 3.5 inches, the width is 21.5 inches.
|CTD phase...put in new support
runs for the work surface plate...temporarily screwed old plate
in...aligned the fences...shimmed for surfaces....
|CTD is ready for use...will design the hood and dust collection later.|
Collection Hood Setup
|Rather than start all over with a hood...I decided to use the shell of left, right, rear and upper panels...I carefully determined the swing needed to chop at the max 50° on both sides...there was sufficient room if I spread the sides outward a bit.|
|I healed the wounds in the roof of the shell with metal tape...and secured the hood to make it flush with the upper shelf at the top.|
|I put put wooden framing in
the lower side panels to secure the hood. This allowed outer
panels to push out a bit as well as up.
|In the back, I scabbed a ledge
and secured the 3 x 10 metal register...taping the rear surface
into the register.
The front edge will be secured to work station base plate.
|Created a new work station plate
for the chop saw...previous plate had sagged some over the
years...so I added rear cross brace...it is attached to
the side braces in case they need to be adjusted.
|The work station plate is 3/4 MDF with a red oak front edge that will help with sag plus keep the front edge from getting abused.|
|Installed plate, screwed down the
vent at the back...it did not work like I wanted so I realigned
the register lip to be lower than the plate...created slanted
|...added front triangle panels to close off the hood area...all crevices will be taped off.|
|Adjusted saw for front/back, left
right, fence alignment, support bench heights, etc. and secured
It is not permanently aligned yet but the
CTD phase has begun...
After usage, final dust issue fixes will be made.
|New blade, Amana Tool Industrial
80 tooth for miter cutting.
|Dewalt accessory hold
down...works best from the front rather than over the fence...
|Even better...MicroJig clamps fit into the base opening and work great.|
|Made a custom zero clearance
insert out of 1/4 inch MDF...
|Custom fit for the Amana blade...
|I needed a hose that would attach
to the outer diameter of the dust port...OD is 1.75
inches...having a 1.75 ID is not a typical dust collection hose
size...not many choices
on Amazon I found an RV battery box vent hose. It is much stiffer than a dust collection hose.
This hose flexed enough to use and it really only redirects the dust thrown through the port down into the dust collection hose...it does not have direct pull from the DC.
|Right side view of the hose going
into the dust collection port...
|Left side view of the hose
attached with a worm drive clamp.
|At straight on 90° cut...the
rigid structure of the hose provides too much friction when
performing the chop action...I put in some strips of
tape...UHMWPE (ultra high molecular weight) polyethylene...
the rub improved but may ultimately require a different hose.
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