Dewalt 611 Deflector and Dust Shoe

thingiverse

The DeWalt 611 is a top-notch router perfect for use as a spindle on CNC machines. One downside to this motor: it relies on air cooling and expels all that dust and debris out of its bottom housing, turning everything into chaos. To combat this mess, I designed a special plate to attach securely to the bottom of the router, deftly deflecting the air upward and away from the spinning spindle. The design even includes an optional mounting for a vacuum hose with a sturdy footprint accommodating a removable, magnetized dust shoe. Users can print just the deflector plate or create the whole kit with the vacuum coupling and dust shoe in one convenient operation. To fine-tune this model to individual needs, simply adjust the SCAD code - although please be aware that the coding system used here is somewhat challenging due to its Python-generated nature. The necessary Python code can be found in my public GitHub repository for your reference. Now let's move on to assembly instructions. Before we get started with installation, you will need a few basic tools: 20mm M4 Socket Cap Screws (x2) M4 close ended tap (x1) Here's the process: First remove the two screw taps from your router. Then remove the yellow button housing and its components. Using the preexisting holes on this housing, use an M4 tap to carefully re-tap them. Please try using a closed-ended tap for optimal results - however if not available a through-hole tap will do as long as you exercise some caution to avoid damaging any surrounding plastic. Now insert the deflector plate into place and make sure it lines up properly with the screw holes. Screw in two 20mm M4 socket cap screws firmly into their respective spots to secure the assembly tightly together.