X-carve Dewalt DWP611 Router Bottom Wood Dust Control Cap

thingiverse

Design criteria: 1. Utilize existing fan mechanism. 2. Maintain original housing, motor, lighting, etc. without modifications. 3. Leverage air flow to control wood dust trajectory. 4. Optimize wood dust removal from tool paths to a maximum extent. 5. Minimize cleanup requirements. 6. Integrate with existing vacuum boot seamlessly. Did I overlook anything? Employing the existing cooling fan's airflow, I crafted the router bottom cap to generate two jets of air directly behind the tool and on either side. This propels wood dust forward effectively. The remaining airflow is channeled into two plenums that expel air horizontally out the front and towards the vacuum system inlet. I precision-fitted the center locator by making its diameter snug and using hot water to render PLA pliable before pressing it into place. This ensures an impeccable fit. After scouring my screw stash, I discovered two screws matching the existing screws' diameter and pitch. I shortened them to about 4mm longer than the original screws. The mount measures 4mm in thickness. The cap does narrow the light cones emanating from the LEDs. Upon testing the design, it effortlessly cleans out tool paths and directs nearly all wood dust into the vacuum system – a remarkable 99% or possibly more.