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Effective control for a notorious sawdust maker
In addition to being versatile, precise and practically indispensable, my sliding miter saw also excels at vomiting sawdust and withstanding effective dust collection. I tried plugging in a shop vacuum, but even when I remembered to turn it on, the vacuum only picked up about half of the dust. I also got tired of reattaching the hose every time it came loose from the saw, a fairly frequent occurrence, due to the saw’s sliding, turning and tilting action. So when I installed a centralized dust collection system in my shop, I decided to try something different.
My collection box is nothing special, but it catches most of the dust. Even if I do not turn on the dust collection system religiously, the captured dust settles inside the box, so it is removed the next time the system is turned on.
I took advantage of the wall behind my saw and the bench it sits on to build my collection box: they serve as the bottom and bottom of the box. You will likely have to tweak the design to make it work for your saw and its location.
Circular saw dust collection box cutting list
Overall dimensions: 16-3 / 4 ″ H x 34-7 / 8 ″ L x 10-1 / 4 ″ D
SP x L x W
1/8 “x 20-1 / 2” x 28-1 / 4 “
3/4 ″ x 9-7 / 8 ″ x 15-3 / 8 ″ (a)
Right end cover
3/8 “x 10” x 15-1 / 2 “
Right side box
3/8 “x 9-5 / 8” x 14-1 / 2 “(a)
3/8 “x 5-1 / 2” x 7 “
3/8 “x 6-1 / 4” x 14-1 / 2 “
Left side box
3/8 “x 9-5 / 8” x 14-1 / 2 “
3/8 “x 6-1 / 4” x 10 “
1 “x 7” dia. (B)
1/4 ″ x 1-1 / 8 ″ x 72 ″
1/4 ″ x 9 ″ x 27-1 / 4 ″
3/4 ″ x 1 ″ x 9 ″
3/4 ″ x 3/4 ″ x 26-3 / 4 ″
(a) The rear edge is shaped to fit the curved front.
(b) Cut to fit inside the CC box.
Create the curved front
I used a piece of leather on the door to make the curved front that forms the heart of the collection box (Photo 1 and Part A, Fig. A). The door skins are only 1/8 “thick, so they are flexible. They are available at home centers in sheets x 3 ‘x 7’ and cost around $ 30.
To determine the overall dimensions of the box and the curved shape of the front, mount one cleat on the wall behind the saw and another on the surface of the bench. Then flex the front and slide it between the cleats (Fig. B). For my setup, the wall bollard was 15-1 / 2 “above the bench and the bench bollard was 10” away from the wall.
To create the ends (B), cut both pieces to size and place one next to the open end of the configuration. Mark the curve of the front on this piece. Then use a bandsaw to cut the curves in both pieces. Drill 3/4 ″ dia. holes in the curved front and then secure it at both ends with glue and nails.
Test the saw to make sure the curved assembly fits the full range of motion. I had to cut a notch at the right end of my assembly, to allow the saw to rotate 60˚ to the left (Photo 2). Since my saw doesn’t rotate as much to the right, I was able to position the box so that the left end didn’t require a slot.
Assemble the box
Attach the curved assembly to the wall and bench. Cut the right end cover (C) to its final size, including the notch for the saw, and secure it to close the right side of the assembly, using nuts and bolts and foam tape to minimize air leaks. This method of attachment allows access to the space behind the curved front, in case it becomes filled with debris or if something important falls through one of the holes.
A plywood box for the dust collection tube (D — G) closes the left side of the assembly. An opening in the side of this box allows the collection system to suck air through the holes in the curved front (Photo 3). To create the opening, one side (D) is shaped to fit the curve of the assembly and the back (E) is cut short. Secure the assembled hose box with nuts, bolts and foam tape.
Make a lid (H) to complete the tube box and a collar (J) to lock the tube. Install the tube and then screw the lid to the box. Install trim pieces (K) to cover all exposed edges of the plywood.
Attach a plywood top (L) to complete the box. To fix my saw, I had to lift the top with the risers (M) and cut the front. My 1/4 “top got slightly bent, so I glued a beam (N) to stiffen it.
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