In my view, adequate dust collection from a tool involves both the design of the tool and the design of the dust collection provisions. The Model R4511 cabinet is a well made, three sided, heavy gage sheet metal design. The fourth side is open and covered with the hinged plastic motor cover. Note the large corner gussets and the ledge that surrounds the bottom of the cabinet. A sloped plastic pan, 3/4” deep at the front and about 6” at the rear, is provided under the saw cabinet for dust collection. An opening in the rear side of the pan was sized for a 4” diameter DC duct.
In my experience, I have found dust collection from a tool to be most effective by eliminating as many corners and horizontal surfaces as possible, so that dust and debris cannot accumulate in those areas. To that end, I added sloped baffles to all sides of the opening in the bottom of the saw. Note that the baffles cover all of the corner gussets and the ledge around the bottom of the cabinet. The baffles were made from 5mm (0.20”) birch underlayment, attached with aluminum duct tape. This material and attachment method provide smooth surfaces that don’t tend to accumulate dust and debris.
Note in the following photo that all of the sloped cabinet baffles channel into a 2 1/2” x 12” duct built into the top of the mobile base. All of the airflow from the saw cabinet flows thru this duct on its way to my 3HP dust collector.
To further minimize dust entrapment, I added a sloped baffle to the motor cover. Even though the motor cover did have a sloped bottom panel, the new baffle was installed with a steeper slope and an overhanging edge to channel the dust and debris into the integral duct. This baffle was made from plastic coated hardboard.
The original dust collection port in the back of the plastic pan was designed for a 4” diameter DC fitting, protruding straight out of the back of the saw. Such an arrangement requires extra space behind the saw for additional elbow fittings and/or flex hose, which doesn’t bend around a very small radius. I designed the integral duct in the top of the new mobile base to accommodate a 6” diameter, right angle, sheet metal furnace duct boot and 6” diameter PVC coupling. This accommodates the 6” ducting used for my overhead dust collection system and allows the flex duct to lie parallel to the back of the saw, saving a lot of space — a precious commodity in my small shop. This flex duct orientation also makes it easier to rotate the saw away from the wall to accommodate long pieces. The 6” diameter duct fitting provides about 225% more area than the original 4” duct, with a corresponding increase in airflow.
Thanks for staying with me—there’s a lot more to come…............
-- Paul, Auburn, WA