Dewalt 735 Chip Collection/Stand #5: Results and Lessons Learned

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Blog entry by Blackbear posted 465 days ago 1811 reads 4 times favorited 19 comments Add to Favorites Watch
« Part 4: Installing the door and filters Part 5 of Dewalt 735 Chip Collection/Stand series no next part

I learned a couple of things right off the first time I used the planer after installing it on this cabinet. The first thing learned was how powerful the Dewalt 735’s blower really was. The door chattered right against the bungie cords.

To fix this issue, I installed a much stronger rachet strap in place of the top bungie. That totally resolved the door chattering issue.

The second issue, discovered after the first, was the single filter I installed was not enough. You could actually hear the motor slow down a little when you closed the cabinet door. There was also some chips blowing back onto the planer table, also indicating restricted air flow and air blowing back. That was the whole reason I built this project, to fix that! Luckily that is an easy fix.

I installed a second filter right next to the first. With two filters, the airflow is much better and there is virtually no chip blow back onto the planer bed. I could also install a third possibly in the future, just to slow the effects of the filters getting clogged. I’m going to get some planning under my belt first before deciding that however. I am curious how quickly the filters will clog. Hopefully not too quickly!

So far I really like the cabinet a lot better than my old setup. You can see from the above picture a lot of chips end up in the bin, but some also blow onto the bottom of the cabinet around the corners. I can live with that.

One thing, pointed out by a reader in the third blog post and verified by me is the cabinet is tippy if you place a long and heavy board just into the beginning of the planer and let it go unsupported. While the planer isn’t really designed to support a 12’ long board like that, I don’t like the cart being tippy anyway. One thing I could do is just setup at least one infeed and one outfeed roller table to support long boards. This would be a good idea anyway. Another idea is to install some kind of fold away legs on the infeed and outfeed sides. Or I could make legs that do not fold away but hover just above the floor, only touching the floor if the cart starts to tip. I’ll have to think about what I want to do for a bit.

I’m still pretty happy with the design and execution so far. Thanks for reading.

19 comments so far

View DIYaholic's profile


12860 posts in 1271 days

#1 posted 465 days ago

Congrats on finishing your “Chip & Dust Collection Cabinet”!!!

All planers need support for longer boards. It’s just a matter of figuring out what will work best for your needs. Time will allow a solution to present itself.

Have fun making (& collecting) dust!!!

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procratination a bad thing?

View lew's profile


9937 posts in 2351 days

#2 posted 465 days ago

Great build!

I think the chip ejector on these planers are from old F-14 Tomcats!

-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View MrFid's profile


506 posts in 500 days

#3 posted 465 days ago

I like the “training wheels” idea to solve the tipping problem, but when it does start to tip do you think that would impact the planer’s performance? I don’t own one of these (someday…) and I have enjoyed your progress on the dust collection method. Great work.

-- Bailey F - Eastern Mass.

View jap's profile


1224 posts in 650 days

#4 posted 464 days ago

great job

-- Joel

View JoeinGa's profile


3088 posts in 603 days

#5 posted 464 days ago

Since I’m gonna be building a new shop and will have to face this same issue as you, I’ve been looking at everybodys ideas for dust collection on the DW75. Right now I have a garbage can catching the chips, but it’s pretty big and unwieldy to move. You can see it here ( )

I really like what you’ve engineered here.

So brainstorming on your model a bit here….

1. If you’re gonna have to pull the green bin out anyway, why not just eliminate it? You could use a shop vac to clean out the chips, or push the cabinet outside and sweep it out.

And 2. concerning the way you put in the hose. The hose is connected pretty close to the same level as the filters, right? How ‘bout if you were to put the hose coming in at the bottom of the box? With a box that small, it’s gonna be like a tornado inside anyway, and without the green bin in it, it’d just swirl around in there and settle to the bottom when you turn it off. I doubt using the metal plate to “direct” the chips matters. In the way that dust is swirling, what’s in the bin is probably just what falls in there when the wind dies down.

-- Perform A Random Act Of Kindness Today ... Pay It Forward

View Blackbear's profile


76 posts in 815 days

#6 posted 464 days ago

joein10asee, you could omit the bin but then when you open the door to check if the cabinet is full, half the shavings would fall out. Then you would have to vacuum them up and empty the vaccum anyways, so why not eliminate that step with a bin? I just decided that for me, emptying a bin outside or even putting a trash bag in the bin would be easier. By the way, my shop is in the basement so pushing it outside isn’t an option for me.

As for #2, I agree the metal deflector is likely not doing as much as I intended it too although I’m going to leave it there anyways. I don’t think all the shavings are airborne while the planer is on. Likely the incoming shavings fly around quite a bit, but when that bin gets half or more full I highly doubt all of the shavings will get airborne when the planer is turned on. If you piped the inlet down low you definitely would be making more of a mess and probably clog your filters faster! One thing I would think about changing is to install some kind of a divider hanging from the top or maybe coming from the side. You would not want to restrict the air flow any, but if there was a good way to keep more of the heavy shavings away from the filters that would be a good change.

Make sure to post some pictures of whatever you come up with!

View DIYaholic's profile


12860 posts in 1271 days

#7 posted 464 days ago

@ Joe,
Some have made a Thien baffle for the DW735, as the blower is powerful enough a DC is not neccessary.

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procratination a bad thing?

View JoeinGa's profile


3088 posts in 603 days

#8 posted 464 days ago

Thanks for the answers Blackbear. I see your point on both issues. Gives me something to brainstorm on when I do mine.

And Randy… yep, the first time I turned mine on it was with nothing attached to the ejector. That blast was like an F-15, and I FOOLISHLY almost put my hand in the air flow “just to see what it was like”. But luckily I came to my senses and didn’t :-)

-- Perform A Random Act Of Kindness Today ... Pay It Forward

View Bigrock's profile


232 posts in 1558 days

#9 posted 464 days ago

I am glad you got the problems solved and you don’t have to have a D.C.. I think you still need the third filter. By the way the next time you are at the Hardware Store pick up some Trunk latches (3) and some thin weather stripping and you can remove the strapping.
Have Fun

View Blackbear's profile


76 posts in 815 days

#10 posted 464 days ago

Bigrock, there is weather stripping all the way around the door. Its just keeping the door against the weather stripping that’s the challenge!

I agree about the third filter, but I’m going to run it for a while and see. I should be able to tell when the filters start clogging by when the chips start blowing back onto the planer table again.

I’ll try asking specifically for trunk latches next time I’m at the box store. I tried explaining to them last time I wanted a latch similar to what you find on metal tool boxes. They couldn’t help me! If I had those, it would be even faster opening the door and probably look a little better. Do the trunk latches both pull the door shut and latch? That’s what I would need.

View JoeinGa's profile


3088 posts in 603 days

#11 posted 464 days ago

Doesn’t Harbor Freight carry latches like this?

-- Perform A Random Act Of Kindness Today ... Pay It Forward

View JoeinGa's profile


3088 posts in 603 days

#12 posted 464 days ago

Or maybe something along the lines of this

-- Perform A Random Act Of Kindness Today ... Pay It Forward

View Blackbear's profile


76 posts in 815 days

#13 posted 464 days ago

That first pic looks like it would work. The second looks too big to mount. Whatever I changed to would have one half mounted on the 3/4” door edge, unless I added some filler piece.

View Thekiltedcarpenter's profile


30 posts in 466 days

#14 posted 464 days ago

My dw735 gave me fits, too, it kept blowing the lid off my large shop vac! Wow! Lots of chip-ejecting force, to be sure. My remedy was to tap into my 4” dust collection system with a 2” wye fitting…by the time it gets all the way to my DC, it is no longer an issue….I really like your cabinet idea as well!

-- Dang! I cut it twice, and it's STILL too short!

View BrandonGonzales's profile


8 posts in 463 days

#15 posted 463 days ago

Hi BlackBear. I just saw your blog and I had to comment. I made a very similar design for my 735 a couple years ago. Mine is a little different as far as the interior bin and wheel setup, so I’ll try to goet some pictures to post.

On the issue of the cabinet being tippy, My cabinet only has two wheels mounted to the back of the cabinet just off the floor. I can lift the cabinet by a handle in front just enough to engage the wheels (think wheel barrow) and it is very easy to move, but when i set it down the whole cabinet rests solidly on the floor. That might be a little hard to follow, so lilke I said, I’ll try to get some pictures posted soon. In the mean time, I drew this high tech sketch to try to show what I mean…

I really like your filter setup. When i get a chance I think I will modify mine to use your setup. The built in chip ejection is my favorite part of this planer since I dont have any real dust collection in my garage shop.


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