Re-Uses #1: Rubber sheet

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Blog entry by ChunkyC posted 02-21-2011 07:56 PM 1934 reads 3 times favorited 5 comments Add to Favorites Watch
no previous part Part 1 of Re-Uses series Part 2: Dog Food »

I was watching one of Marcs videos the other day and he was using his chop saw to cut the end off of a board. The video was a very tight shot of the saw, I assume it’s a Festol. What I saw was that his saw had a factory rubber “boot” of sorts that was behind the blade used to direct the dust up and into the waiting dust extraction system. The rubber was soft enough to easily bend and yet had a memory to it so that it returned to it’s normal self.
We use rubber sheeting at work when we need to protect power wires that may rub against something and damage the outer insulation. So I asked one of the electricians if he would cut me off a small square.

The square ended up being about 9”. I didn’t measure the thickness of the rubber but its in ballpark of 3/16” or so. I used some double sticky back tape to hold it in place while I figured things out. I then drilled and added 4 1/8” rivets to hold it in place permanently. It looks a bit cobbled together but it works quite well. Without the rubber, I doubt that the vac picked up any of the dust. If it did, it was minimal. It still doesn’t get 100% of the dust but it is an improvement on the order of 1,000nds times better than it was.

Maybe you can do something like this if you have the same problems that I do with dust collection on chop saw / CSMS / et. al.


-- Chunk's Workshop pictures:

5 comments so far

View bigike's profile


4052 posts in 3318 days

#1 posted 02-21-2011 08:50 PM

Very neat idea, Thanks for the post.

-- Ike, Big Daddies Woodshop,

View Manitario's profile


2630 posts in 2912 days

#2 posted 02-22-2011 02:56 AM

Interesting that this works for you; I’ve tried this on my MS and just found that having it straight like that results in the dust shooting off the blade into it and then rebounding back at me.

-- Sometimes the creative process requires foul language. -- Charles Neil

View ChunkyC's profile


856 posts in 3283 days

#3 posted 02-22-2011 03:42 AM

Rob: You may not have yours long enough? It should flatten out when your cutting and “scoop” the air in around the sides, or at least mine does. Also, you may need more suction from your dust collection??

I’ve the idea for a long time, it just took me seeing Marc’s Festool to turn the light on for me. When I run the saw, I could see the dust shooting up into where the vac was but it also went all over the place. I just didn’t know what to do about, then I saw the Festool.

There was thread on here today where someone posted a link to a video. The tail end of the video was a guy doing the exact same thing as mine. Only his wasn’t cobbled together like mine is. His worked ok. I think mine works a little better because I think mine flattens out a bit more.

-- Chunk's Workshop pictures:

View racerglen's profile


3112 posts in 2810 days

#4 posted 02-22-2011 03:12 PM

I’ve been using old inner tube for years as “mud flaps” off the back of my
bench grinders, just duct taped on. It keeps the grindings to a much more manageable area, easier to clean up.
I wonder if that type of rubber would work here as well ?

-- Glen, B.C. Canada

View ChunkyC's profile


856 posts in 3283 days

#5 posted 02-22-2011 08:07 PM

I think a piece of inner tube would work just fine.

I got thinking about how I have mine is installed compared to the videos of the others that I’ve seen. Mine is definitely a lot bigger than the others that I’ve seen especially by how far forward it comes.

-- Chunk's Workshop pictures:

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