Popular Post Andrew Pritchard Posted September 28, 2013 Popular Post Report Share Posted September 28, 2013 When I built my exact width dado cutting jig for my router I found it would chuck chips and dust out along the dado that had just been cut. This resulting a lot of mess, and of course untold dust into the air in my shop. So I built a dust shroud to collect as I route. This is actually mark 2. When I built the first one, I put the dust port too close to the router so I couldn't fit the hose properly. With mark 2 you still have to remove the handle on the router, but you can use the dust hose as a handle. Used mark 2 for the first time today, and it worked like a charm. Only a few chips right at the beginning of the run, but once you get the hose over the rest of the cut the dado forms a neat channel right into the hose. One day I might build one out of polycarbonate so I can see better what I'm doing, but this will do for now. Making one is easy. * Remove the existing base * Select the material you're using to build the base out of. It needs to be as thin as possible. I've got some old wood paneling we stripped out of our house which works really well. * Use the existing base of the router to draw out the shape of your base, and locate the mounting screw holes for your router, and drill them out. Test the location of the screws by mounting your router onto the new base. * Cut a 2 1/2" hole in an off cut, then cut the hole out. This will act as a mount for the dust collection hose. I used a hole saw, and then ran my spindle sander round the inside to make a snug fit for my hose. * With the router mounted on the new base (consider removing one of the handles if you can so the hose can be located closer to the router), locate a suitable spot for the dust collection mount. Check that you can mount the hose without it interfering with the router (which is the mistake I made with mark 1). * Extend the lines from the edge of the router out to incorporate the dust collection port. * Remove the router from the shroud, and glue the dust collection port in place on the shroud. * Once the glue has dried, cut out the new shroud with a bandsaw or jigsaw * Use a drill and a flush trim bit to cut out the hole in the base so the dust can be collected easily. * Remount the shroud onto the router with the smallest router bit you have in the collet. * Turn on the router and use the router bit to drill through the new shroud to locate the center. * Finally remove the shroud from the router and use a drill to widen the hole so that it's big enough that the collet can pass through the new shroud. You also need to provide a little space for the air to flow down the newly cut dado. My collet is 1" across at it's widest, so I cut a 1 1/8" hole. Enjoy! 3 Quote Link to comment Share on other sites More sharing options...
PeteJr Posted September 29, 2013 Report Share Posted September 29, 2013 I've been searching for ideas on handheld router dust collection and your approach is very good. Many times you can fabricate a solution in the shop and this is a great example. 1 Quote Link to comment Share on other sites More sharing options...
Andrew Pritchard Posted September 29, 2013 Author Report Share Posted September 29, 2013 The dust collection on my router is ok, but it sucked (or rather didn't suck) for doing dados. Hence the jig. Also 2 1/2" is more effect that the 1 1/4 my existing shroud uses Quote Link to comment Share on other sites More sharing options...
Spencer_J Posted October 4, 2013 Report Share Posted October 4, 2013 this is awesome! totally dig the simplicity of it. 1 Quote Link to comment Share on other sites More sharing options...
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