Dewalt 611 CNC Dust Shoe

thingiverse

After trying the original, I re-imagined its design and came up with this complete remix. Although it worked well initially, I encountered several issues that I decided to fix with my own unique design. One major change was moving the hose attachment from the side to the front of the machine. This reduced the usable width and allowed me to position it in front of the router instead of the side. However, the original design wasn't symmetrical, which triggered my OCD. Within a few days, the pin on the original broke, so I started using the Dewalt ring to adjust the height. While it worked well without the pin, the original would sometimes slip out of the ring. To fix this, I thickened the interface slightly and now they snap together snugly. The most significant change is the brush ring. The original used a rigid brush strip from McMaster that was extremely difficult to work with. I modified the design to use a flexible brush that's much easier to handle. It requires approximately 11 3/4 inches of the brush strip, just shy of the minimum order length of 12 inches. To mold the flexible brush, heat up a bowl of water in the microwave for several minutes and then place the brush strip in the hot water. After 30-60 seconds, remove it from the hot water and insert it into the dust shoe, shaping it to fit perfectly. Allow it to dry completely and verify that it's taken the correct shape before securing it with a touch of hot glue. The 1-inch brush strip can be ordered on McMaster.com, while the 2-inch brush strip is available on the same website. My design in the photos was printed in ABS and finished with an acetone bath. I'm using a 35mm Bosch hose that works great and can be purchased on Amazon.com.