Dust Collection For An Old Bandsaw

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Project by tyvekboy posted 06-10-2012 10:49 PM 6106 views 10 times favorited 12 comments Add to Favorites Watch

June 11, 2012

If any of you own a bandsaw thatʻs about 40 years old, you know that back then they didnʻt make them with dust collection in mind. The lower wheel guard is so loose fitting that sawdust ends up every where.

This got me thinking of the following solution.

I didnʻt want to modify the original lower wheel guard so I used it as a pattern and cut a blank out of 3/4 inch plywood scrap. As you can see I added some wood around where the blade comes through the bottom of the table. I then located the holes through which the hanger posts would pass through the cover. The threads on the hangar posts are not very long so I had to allow for that.

What I did was I recessed a piece of stiff metal even with the back of the lower wheel guard and attached it with short screws.

There is a hole about 3/4 inch deep and about 7/8 inch in diameter on the front side of the lower wheel guard through which the knob is screwed to hold the guard.

The depth of the hole made the original knob that screwed on the hanger posts to hold the original lower wheel guard in place obsolete so these knobs had to be made. Notice the longer neck on my purple knob.

These knobs were made with a 3/8 inch coupling nut and piece of plastic that I fashioned that had a hex hole in the center and was snug enough to stay on the end of the coupling nut.

I then test fitted this assembly before proceeding.

I glued a flange to which a dust-right adaptor would be attached. The flange was cut out of 2 pieces of 3/4 inch plywood laminated together. To make this guard lighter I cut lightening holes in the 3/4 inch plywood leaving enough wood to glue a 1/4 inch plywood to cover the holes.

Here is a shot of the dust-right adaptor attached.

This is what the guard looks like with the 1/4 inch plywood attached.

This is what the inside of the finished guard looks like. To finish the guard I made a shroud out of some stiff metal that was custom fitted to get as close as possible to the lower frame of the bandsaw. The shroud was attached with short pan head screws. Then self adhesive weather stripping was attached to create a seal to minimize air leakage to improve better dust pickup around the blade. You can barely make out the black weather stripping in this photo.

This is the outside view of the finished lower blade guard. To make it prettier, I made a swirl pattern on the metal shroud with a tool that I had to fabricate.

Left side of the lower wheel guard installed.

Right side of the installed lower wheel guard.

All comments welcomed. Thanks for looking

-- Tyvekboy -- Marietta, GA ………….. one can never be too organized

12 comments so far

View John Stegall's profile

John Stegall

457 posts in 2608 days

#1 posted 06-10-2012 11:18 PM

Tyvek, great work. Care to share more about your “swirling” tool? There Is probably a more correct term for it, but it escapes me.

-- jstegall

View HillbillyShooter's profile


5546 posts in 1384 days

#2 posted 06-11-2012 01:32 AM

Great idea!

-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington

View Jim Jakosh's profile

Jim Jakosh

14432 posts in 2197 days

#3 posted 06-11-2012 02:49 AM

Great design. A man after my own heart the way you make things!!
John, that is called engine turning on the metal!


-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View dclark1943's profile


213 posts in 1279 days

#4 posted 06-11-2012 09:30 PM

Wow, pretty cool—good old “necessity is the mother of invention” nicely done. I love your attention to detail.

-- Dave, Kansas City

View tyvekboy's profile


974 posts in 2105 days

#5 posted 06-11-2012 11:36 PM

John—I just posted another project describing the “swirly tool”. It’s not fancy but it works.

Thanks to others for your kind comments.

-- Tyvekboy -- Marietta, GA ………….. one can never be too organized

View Nate Meadows's profile

Nate Meadows

1079 posts in 1298 days

#6 posted 06-11-2012 11:44 PM

Great work! Thanks for the information.

Thanks for your service…you might have flown me around:)...but seriously thank you!

Very Respectfully and Gratefully,


-- "With a little bit of faith, and some imagination, you can build anything!" Nate

View scarpenter002's profile


575 posts in 2997 days

#7 posted 06-16-2012 02:37 AM

Great idea and great execution Alex. Thanks for posting.

-- Scott in Texas

View Mauricio's profile


7077 posts in 2243 days

#8 posted 08-07-2014 01:17 AM

Hi Alex, do you only collect dust by the wheel or do you have anything to collect the dust that falls out right below the table?

I was looking to get a Y connector to run a length hose to collect below the table as well as on the wheel cover. Then I said to myself, what would Alex do? I bet he would make his own Y connector and duct hood out of plywood. :-)

-- Mauricio - Woodstock, GA - "Confusion is the Womb of Learning, with utter conviction being it's Tomb" Prof. T.O. Nitsch

View tyvekboy's profile


974 posts in 2105 days

#9 posted 08-07-2014 03:16 AM


Before I made the modification, there was dust everywhere. After the modification, the dust was considerably less. I donʻt think trying to collect the dust that comes out below the table by the blade. It wouldnʻt hurt if you do. Now if you want to, you can either try to make one like I do with stacked plywood or you can go to ROCKLER and get the adapter that they sell for router tables.

Here is the link:

Youʻll also have to get the short piece of hose and figure out a way to hold it by the blade.

Like I said, I donʻt think itʻs worth the trouble for the amount of dust that it will collect.

Also such a big adapter might get in your way as it will stick out quite a way.

Hope this helps you decide.

-- Tyvekboy -- Marietta, GA ………….. one can never be too organized

View Mauricio's profile


7077 posts in 2243 days

#10 posted 08-07-2014 03:35 AM

Yeah something like that is what I was thinking about. I’ve actually been getting a lot of dust falling below the table which is why I need it. Thanks for the advice and the link.

-- Mauricio - Woodstock, GA - "Confusion is the Womb of Learning, with utter conviction being it's Tomb" Prof. T.O. Nitsch

View JoeinGa's profile


5651 posts in 1099 days

#11 posted 02-11-2015 10:01 PM

Nice setup! Question… Why did you cut out the 3 odd-shaped holes in the plywood, only to cover it with the 1/4” ply? Why not just leave the 3/4” ply intact? The way it’s mounted, I doubt the weight would make much difference?

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

View tyvekboy's profile


974 posts in 2105 days

#12 posted 02-12-2015 03:34 AM


I’m getting old and the lighter I can make things the better. It’s heavy enough as it is with the cut outs. Then again I could be wrong …..

-- Tyvekboy -- Marietta, GA ………….. one can never be too organized

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