"Popular Woodworking"s Band Saw Dust Collection - Overkill?

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Forum topic by GrizzlyBagWorks posted 08-02-2015 06:44 PM 3245 views 0 times favorited 6 replies Add to Favorites Watch
View GrizzlyBagWorks's profile


91 posts in 1619 days

08-02-2015 06:44 PM

Topic tags/keywords: dust collection band saw bandsaw dust collection popular woodworking dust collection

Hi guys, so I’m looking to upgrade the dust collection on my Rockwell 14” bandsaw. I installed the standard ‘dust collection’ port that many band saws come with and even with my HF DC it made little difference.

Initially the plan was to cut out a 2.5” hole in the lower left corner of the bottom cover and just install a 2.5” dust collection port but I’ve read mixed reviews about that method so I’ve been thinking about something a step above that would utilize my 4” hose.

I ran across the “Popular Woodworking” setup and it looks pretty good . Does anyone have any experience with this method? I can’t find any info on that mod and haven’t seen anyone else do anything similar. Here’s what I’m talking about.

Any other ideas that may be better than this one? This thing spewwws sand dust worse than any other tool in my shop! Thanks guys!

6 replies so far

View Fred Hargis's profile

Fred Hargis

5002 posts in 2521 days

#1 posted 08-02-2015 08:32 PM

That’s very much like the optional DC connector that Delta used to sell. I haven’t used one, but have seen many comments that it works very well. I opted to cut a hole in the lower door and put a flange on it. Even though it’s 4”, and I have a big DC…I call the performance only adequate, not great. Your plan to use a 2.5” hole won’t be so much of an improvement over that ridiculous factory port, it’s very hard to move enough air through 2.5” for a BS (just my opinion). BTW, when I hooked up to my door, I also put a plexiglass cover where the OEM port was, that was to direct airflow more than to seal the opening. Lastly, to answer the question: I don’t think what PWW suggests is overkill.

-- Our village hasn't lost it's idiot, he was elected to congress.

View Kazooman's profile


1031 posts in 1980 days

#2 posted 08-02-2015 09:31 PM

How do you attach the unit to the saw? Do you have to cut out some of the lower door? My Delta saw didn’t come with any dust collection port. Like Fred, I decided to add a port. I mounted a 4” flange style port on the lower right door. It helps, but there is still a bit of a sawdust problem. I just checked the saw and there is a little sawdust at the bottom of the inside below the lower wheel. I think the problem is not so much the size of the port and/or the capacity of the dust collector, as it is with the limited airflow possible through the case of the saw. In looking at it there really aren’t many good places for any make-up air to enter. I’ll have to think some more on how to get a good flow of air through the lower part of the case to increase the efficiency of the dust removal.

For what it’s worth, the design with a port drawing on the side of a 1 5/8” box doesn’t look to me like the best way to get good air flow. Even tees in a 4” line reduce the flow. If you are going to go to such lengths to construct an adapter for your saw, I would try to find a way to have the port in line with the long dimension of the box, basically drawing straight on the blade and wheels, not at a 90 degree angle. My front door mounted port at least draws as close as is physically possible directly where the blade meets the lower wheel.

View GrizzlyBagWorks's profile


91 posts in 1619 days

#3 posted 08-02-2015 11:57 PM

Thanks for the feedback guys.

Ya, you have to cut away most of the side of the cover and the outflow occurs bascially along the entire right side of the wheel. Here’s a better photo and a link to the original page:

View poospleasures's profile


743 posts in 2512 days

#4 posted 08-03-2015 02:42 AM

The fixture I use on the band saw for dust collection is very simple, very effective and costs so little. Like most of us I have worked on this problem a long time. Sometimes simple is best.

As most 14” saws are very similar this should work for most of you but it is not pretty. I only made one small cut in the lower door at the top. and bent that section forward to allow free flow of the dust. In my case I used a 90 degree plumbing fitting with a 4” inside dia.

You do have to cut some slits in the fitting to fit your saws under structure.

You can then experiment with heating( lightly with a propane canister) to bend these relief pieces to fit around pieces of the saw tables under structure.

Then use some thick rubber pieces mounted to the formed fitting to try hard to seal it to the bottom of the table.

Now you must find a way to hold it in place. In my case I use a small bungee cord attached to the fixture and then wrapped around one of the table adjuster knobs and its hook put into a small hole drilled in the edge of the table top. This fixture allows me to catch at least 95 percent of the dust as it is made. Works even better if the pieces you are cutting are large enough to leave the blade insert out. Hope this helps. If you have more questions PM or ask here.

-- I,ve had amnesia for as long as I can remember. Vernon

View timbertailor's profile


1594 posts in 1452 days

#5 posted 08-03-2015 01:26 PM

Adding a four inch port in the bottom of the cover works really well. Another port below the blade is also very helpful.

-- Brad, Texas,

View rwe2156's profile


2967 posts in 1509 days

#6 posted 08-03-2015 01:42 PM

Seems to me like its not in the optimal place, is it?

Timbertailor’s setup above seems more efficient as the dust will be falling off the blade at the bottom of the wheel.

Personally, I don’t worry about it, I just pop the door open every now and then and vaccum it out…....

-- Everything is a prototype thats why its one of a kind!!

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