I took inspiration from Paul Stoops (fellow LJ) who improved his TS dust collection.
I have a Ridgid R4511 that I wanted to improve the overall dust collection, (some photos show motor covers off since I had a capacitator go bad that I had to replace during the project), since completing this the upgrade has been tremendous, I don’t know of any saws that have as good of collection as this home-made upgrade. Enjoy. (its always better when you make it yourself)
My dust collection varied a little from Paul’s. I have a 4 inch dust collection hose that runs to my machines (single machine usage), so I didn’t want to reduce from 6 to 4 at the machine. I had a local HVAC guy order me a 10” x 4” x 2.25” dust end-boot which worked great. I attached my PSI quick disconnect to the end boot and it looks very clean. I cut out a little of the material on the existing plastic saw opening to increase its size opening a little and then bolted a piece of hardboard with gap filler to the DUST BOOT to attach it to the saw as is seen in the photos.
I then JB weled two pieces of wood above and below the outlet and pipe clamped it together. I put a piece of wood behind the 4 inch outlet to act as a spacer to keep it from moving (can just see the wood in the photo). Very SECURE.
I epoxied the hardboards in place and then ran metal foil (duct) tape over all the seems to smooth all the edges.
One variation on my from Paul’s was that I wanted to be able to easily open the motor hinged cover on the side so I added a board on the bottom to elevate the sloped hardboard so that way when I extended it over the edge of the saw opening it wouldn’t hit when opening and closing. I am also going to add some of those Reid Supply company SC-1919 swell latches, however the suction is so strong it isn’t even needed.
I added foam under the granite top and steel base where there was just a little space it really helped seal it all up, in the lower right opening of the hinged door I had a very small gap issue so i added a little adhesive backed foam.
The slot that the angle guide and wheel adjustment travel on the front of all saws is a large slot, huge air suction loss spot. I used a thin vinyl magnet (adhesive on one side) I attached orange paper to the adhesive side of the magnet to match the saw. I cut them so they can be adjusted to any blade angle and still seal the slot opening. The naturally attach and hold well to the steel base, works great. With all these improvements the suction power is just awesome, incredibly strong.
Some of the photos are taken out of sequence as far at the build goes, in the end all sides are sloped with no flat edges to catch any dust. I made this for a Ridgid R4511 however any saw cabinet style or hybrid can be modified using ideas such as this, hope this helps and enjoy.