DeWalt DW708 Mitre Saw "Dust Extractor"

thingiverse

My father-in-law is a gifted craftsman and artist who creates intricate stage sets for his local community theaters and schools. He has a spacious workshop right outside his door, fully equipped with a well-stocked wood shop. Recently, he asked me to recreate the Dust Extractor nozzle for his cherished DeWalt DW708, which he had been using for years. The part is fragile and had been damaged multiple times, prompting him to discover that DeWalt had discontinued it, labeling it as "obsolete" with no replacement available. Since I couldn't visit him in person to examine the saw, we relied on mail deliveries to exchange parts back and forth. I carefully measured the original nozzle and used Tinkercad to replicate its general shape. Although Tinkercad may not be the ideal tool for industrial design, I'm familiar with its capabilities and appreciate its affordability. To ensure a secure fit, I increased the dimensions of the mounting flange, requiring longer bolts than the originals. However, my first iteration was too long, causing it to bind when inserted into the saw. After receiving feedback on how version 1 performed, I made some subtle adjustments to the mounting face, resulting in a second version that reportedly mates with the saw better than the original nozzle.