Slim Dewalt DWP611 Thread-On Dust Shoe for Shapeoko

thingiverse

UPDATE (20180123): Added a V2 of the shoe body that brings the vacuum hose nozzle a little further from the router. This should allow for the router height in the block to be adjusted without conflicting with the shoe. Overview This is a remix of the 'Dewalt DWP611 Thread-On Dust Shoe for X Carve' by nmackes: http://www.thingiverse.com/thing:1243484 Here's a quick list of the modifications I made: - Removed vinyl ring - Removed mounting holes for vinyl ring - Added channel for nylon conveyor strip brush (link below) - Removed quick release clip - Added M3 screw to 'lock' shoe in place - Added rectangular duct in place of vacuum mount The rectangular duct is designed to wrap the Shapeoko 3's spindle block so that the vacuum hose can be attached as close as possible to the spindle. This allows for the dust shoe to have a slimmer profile and not protrude too far beyond the front of the spindle. Additional Parts I used the 1/8" general purpose, nylon bristles conveyor strip brush for this build (https://www.mcmaster.com/#catalog/118/1256/=icpe4p). Any height could probably be made to work but I think the 2" (74715T3) height is ideal. The height can always be trimmed later. One shoe will require a little over 1ft of brush. I bought 3ft for about $23, delivered. The lock screw that I used is a metric M3 with a press-fit chevron insert like this (http://a.co/2VGENhm) although I actually use the Tri-Star brand. These are a great option for incorporating fasteners with 3D parts and vastly superior to tapping thru-holes and/or using hex-nuts. I only have one vacuum hose to use with this shoe so I didn't make a lot of different sized friction fittings but that's not to say that you couldn't print an adapter. Here's a link to my hose if you're curious (http://a.co/854FD7u). To reduce the overall height, I trimmed my hose nozzle to about half the original length. Post-Printing Clear Supports Clean up is pretty easy, this build requires minimal supports. All supports can be easily cleared without special tools although I do like to use X-acto knives and dental tools to remove tiny bits of support material in those hard to reach corners. Add Lock Screw To install the lock screw and chevron insert, first make sure that the holes are clear of any extra support material. The holes should run slightly small but that's desirable because material can always be removed later. The easiest way to install the chevron is to thread it onto the end of a long screw and hold it with pliers. Using a heat gun, warm the chevron until it's about 200C, it's safe and easy to do if you hold the screw with the pliers. This should only take a few minutes. While the chevron is still hot, press it into the hole on the shoe adapter. Be mindful of the screw angle, keeping it straight so that the screw will thread the chevron when inserted into the slot on the dust shoe. Add Conveyor Strip Once the conveyor strip channel is cleared, it can be bent to fit the channel and glued in-place. I used the channel from a failed print to help get the bend radius right but you could also make a jig. The tricky part with the conveyor strip is getting it to bend while keeping the channel straight. It took a little bit of work to get right. I used hot glue to secure it in place. Completing the build From this point the parts can be assembled in the same fashion as the original dust shoe. Thread the dust shoe adapter onto the bottom of the Dewalt router until it's nice and snug. To get the orientation correct, I had to adjust the router in the spindle block until it was just the right height to be tight and face forward. Add the dust shoe and the lock screw, then insert the vacuum hose. The vacuum hose should be a friction fit. If it's a little too loose, try adding some tape or a shim. If it's too small, an adapter can be used. Please let me know how it works for you! I try to be thorough with my projects and feedback is always appreciated, let's just keep it constructive! Thanks! One last shout out to nmackes! All I did was put my own twist on this design, credit goes to nmackes for the core design concept.