Router dust collector - 3D printed my own

[kahlid74]

I've posted a few times about dust in the workshop and one of the worst offenders is the router.  Since my starter Ryobi plunge router is still working well I decided instead of buying a bosch and then the dust tray systems I would try my hand at building my own.  So I used Sketchup to build the part, then used Netfabb to make sure what I built in sketchup had volume and no messed up triangles in the mesh.  My larger 3d printer is down right now so I printed it in three parts.  Below are the pictures:

Here was the original design:




After several trips in and out of Sketchup/Netfabb here's what I settled on:







The nozzle for connecting to the shop vac was printed seperately because while an accurate measurement could be taken of the hose, the 3D printer printed fill and as the ABS cooled it expanded in a way I didn't expect originally.  Which meant a trial and error.



Thoughts in the end:
I had a lot of fun doing this and learned even more than I knew before with regard to CAD/Meshes/Etc.  I made the hopper .3" thick and now I would probably do .2" since the .3" is super sturdy.  The hose inlet was a beast.  The original design did not pan out and I wound up making this one in the end.  It took as much time as the rest of the piece because trying to do skewed 3d objects in sketchup is a pain in the rear.

As far as affixing the hopper to the router, I just used a bolt through the router hole and then a washer and nut.  Airflow wise I would have liked to use a flat screw but in the end this proved to be easier and more sturdy.

The clear line you see in the middle IS NOT GLUE.  It's better to bond plastic to plastic with plastic instead of glue.  So for adhesion it is recommended you mix acetone and ABS scraps to create an "ABS Slurry" which is a milky substance that you brush onto the part and then hold them together.  The acetone melts both sides and then dries quickly.  Similar to welding or the glue/woodglue process.  It basically acts now as one piece of plastic.

How does it work?
Awesome!  Little to no dust anywhere and a small amount in the corner of the hopper which indicated the shopvac isn't strong enough suction wise.  This jives with the filter needing replacement.

I plan to do a version 2 with a 4inch inlet so I can use it with my Clearvue cyclone but that will be a bit out.  I also plan to upload the STL files to Thingsverse/Non makerbot repository for anyone else who wants one.


Forgot to add a picture after first use.  Time to get a new filter for Mr Shopvac.

[spoot]

Nice!  Just finishing up my garage as well to redo my workshop...and dust collection high on the list.  I'll have to ponder this for some of my routers.  Have cyclone cans in front of the DC's now...and man, what a difference.

[TopJimmyCooks]

1 - that is awesome.
2 - the dust in the corners is because of the boxy shape - constant vortices in there.  it would be very easy to drill a couple of carb holes in there and keep the inside of the box cleaner.  I know skews are hard in sketchup, but what about just clipping the corners to make a square funnel towards the hose outlet?

[sleong]

Very nicely done!

I'm sure that keeps the workshop a lot cleaner when using the router!

[Rick]

I always toyed with this type of design. (I just drew this up quickly - it's not to scale, and obviously doesn't have the proper holes for the screws to attach to the router base.) I'm sure I had seen it somewhere before, and I definitely like the simplicity of the design. You can modify it to include handles, if you want, or change up the size of the extraction tube for different size hoses.



Just clamp, turn on the vac, and go.

[wp34]

That is just too cool.   

I routed some MDF today.  I forgot how dusty it gets.  How soon will you be selling these?   

[Rick]

That is just too cool.   

I routed some MDF today.  I forgot how dusty it gets.  How soon will you be selling these?   

Lol. I'm selling everything these days, aren't I?

[kahlid74]

I always toyed with this type of design. (I just drew this up quickly - it's not to scale, and obviously doesn't have the proper holes for the screws to attach to the router base.) I'm sure I had seen it somewhere before, and I definitely like the simplicity of the design. You can modify it to include handles, if you want, or change up the size of the extraction tube for different size hoses.



Just clamp, turn on the vac, and go.

Rick,

That is the design used on CNC machines.  It woks great for routing joystick depressions and other in wood routing where the router is flush with the entirety of the surface.  It however does not work very well with flush trim bits or slot cutters.

These bits extend beyond the assembly which is why you want to only go up to half of the router so you have a hopper to catch the dust.

[Rick]

That is the design used on CNC machines.  It woks great for routing joystick depressions and other in wood routing where the router is flush with the entirety of the surface.  It however does not work very well with flush trim bits or slot cutters. These bits extend beyond the assembly which is why you want to only go up to half of the router so you have a hopper to catch the dust.

Soooooo, like this?

[kahlid74]

That is the design used on CNC machines.  It woks great for routing joystick depressions and other in wood routing where the router is flush with the entirety of the surface.  It however does not work very well with flush trim bits or slot cutters. These bits extend beyond the assembly which is why you want to only go up to half of the router so you have a hopper to catch the dust.

Soooooo, like this?

For flush trim and slot cutter bits no, that won't work either.  Basically they need a vacuum at a perpendicular angle to them because they are spitting saw dust out in such an aggressive manner.  Anything less and you won't have the direct suction you need to capture the fine dust particles.