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upgraded the dust collection on Bosch table saw

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Forum topic by juicegoose posted 03-01-2011 04:28 AM 12306 views 10 times favorited 39 replies Add to Favorites Watch
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juicegoose

113 posts in 1811 days


03-01-2011 04:28 AM

Topic tags/keywords: dust collection bosch 4100 table saw upgrade

I’ve loved my little Bosch 4100 table saw but have always found the dust collection lacking. A while back i found an article on fine woodworking regarding closing up these little jobsite saws to catch the dust. I set out over the weekend to upgrade the dust collection and this is what I came up with.

1. I added a zero clearance insert and sprayed some slow expanding foam under the table where there were cracks between the table and the base. I did this on the front and back edge but let the edge by the motor stay free so when the dust collector was on it would try to pull air mainly from the motor side of the housing. I did this for two reasons
1. To keep the motor cool with fresh air flow
2. The air being sucked into the base would create turbulance and get the dust up in the air for removal.

Next i cut out some covers for the front and back face of the base assembly and stuck them on the saw with velcro so when i wanted to cut at a 45 degree angle i could simply take them off. This velcro didn’t stick well and I’ll be using some magnets next.

I then added a piece of 1/4” ply between the gravity rise stand and the base of the saw to close off the bottom. At the same time i noticed that the most effective place a dust collection fitting would attach to the base was in a area that had me turning the saw around on the base. I mounted the dust collection fitting to the 1/4” ply with 1/4” bolts(overkill but it is what i had on hand). Don’t forget to cut out the hole under the fitting either.

Lastly i attached a section of 2.5 flex hose to a 4” x 2.5” wye fitting and attached a 4” main trunk to the under cabinet side of the the base.

Hooked all up to the dust collector this badboy stays clean as a whistle. It’s a vast vast VAST improvement and I can still fold the saw down too!!

Hope the pictures help to explain my ramblings.


39 replies so far

View NBeener's profile

NBeener

4806 posts in 1922 days


#1 posted 03-01-2011 04:51 AM

Beautiful job !!

I’ve got the 4100, and have achieved a BIG improvement with nothing more than blue painter’s tape.

But … you may just have inspired me :-)

Thanks for sharing !

-- -- Neil

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BTKS

1971 posts in 2213 days


#2 posted 03-01-2011 06:34 AM

I have this little bad boy too. I haven’t really considered the dust collection either way. Just had to chime in about loving the saw. I use it combination with my cabinet saw to run a dado blade on if I have a lot of rabbets to do. I may use your improvements if I get into a job in a house or area I want to keep clean. Thanks for the ideas.

-- "Man's ingenuity has outrun his intelligence" (Joseph Wood Krutch)

View juicegoose's profile

juicegoose

113 posts in 1811 days


#3 posted 03-01-2011 05:33 PM

You know one thing ‘ve noticed on at least my saw is that when i attempt to change to my dado stack it’s very hard to get the stack on the arbor. Seems like either the dado stack is to small or the arbor is a little large. I know this isn’t true but still a pain to change as the blades get stuck.

View will delaney's profile

will delaney

321 posts in 1384 days


#4 posted 06-24-2011 08:48 PM

It’s been some time since you have posted this and I am wondering if you have made any changes. I have just finished working with some Paduk and got to the point where something has to be done. Red sawdust all over. Pretty but also scary. Thanks for this post.

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juicegoose

113 posts in 1811 days


#5 posted 06-24-2011 09:04 PM

Willd Sure haven’t made any change to the general arangement of things. It works amazingly well. I would say around 90 to 95% collection. I did go back and remake my little covers for the front and back. The new covers I made had magnets in them. The front cover will stick straight to the case but the back I had to epoxy a magnet on the inside of the plastic saw case and one in the cover. Works great other then the fact that on the back case one of my magnets is turned around backwards. Ahhhhhh I’m dumb!!!

I Highly recommend you do the upgrade.

Also make sure when you put the lower collection fitting in that you account for the swing of the saw on it’s mobile stand. I simply folded everything down and then stuck the fitting on the wood traced around it and cut it out with a saw.

Also I can’t remember if I kept it this way but I know at one point in the design I had turned the saw around on it’s mobile base. Maybe to try and get the fitting a little more centered or something. I’ll look this evening bu just remember to put the big fitting on the side of the saw opposite the motor so it will suck the dust bfore it even hits the blade shroud.

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will delaney

321 posts in 1384 days


#6 posted 08-07-2011 01:06 PM

I finely got around to make the mortification on my Bosch TS. I can’t believe the difference. This has cut my cleanup time in more then half giving me more time to do what I like, woodworking. One would think that Bosch would sell this mortification as an accessory. If you own this saw I don’t know how you could live without making these changes. Thanks juicegoose for all the info and instructions. Will

View Flyin636's profile

Flyin636

57 posts in 1242 days


#7 posted 08-07-2011 01:21 PM

Nice job!

Just wanted to add,anyone looking for a cheap supply of “thin’ish” rubber for use in this area(dust control around equip openings)....and it works very well on equip like shapers around cutter head….is;steal your wife’s Yoga mat,and cut it up into required pcs.Well,reckon you “could” go buy one…..but whats the fun in that?BW

View Retrowood's profile

Retrowood

117 posts in 1167 days


#8 posted 10-12-2011 06:53 AM

I’m new to the forum and actually found this site by searching for improvements on Bosch 4100 table saws. Excellent post, just wondered if there are any updates on your modifications? I’m currently using a older Jet Contractor saw which is getting the best of me over dust collection or lack of it. Seems like everything thing I’ve done to improve things has actually made things worse so far. Since my shop is small and I need something with reduced dust output, I’m thinking of selling the Jet and going to the Bosch unit and making the same mods you’ve done to help with the dust collection.

Thanks, Retrowood

-- Retrowood

View juicegoose's profile

juicegoose

113 posts in 1811 days


#9 posted 10-12-2011 03:35 PM

Welcome to the site retrowood. To answer your question no I haven’t done any further upgrades. The collection works great and I couldn’t be happier. If your looking for a great saw the 4100 is tops. Do a search and you won’t find a better reviewed portable saw. That said it is kind of pricey. If money isn’t an issue or you would like something portable yet robust and most importantly accurate then go get you a 4100. Let me know if you’ve got any questions about the saw.

View Retrowood's profile

Retrowood

117 posts in 1167 days


#10 posted 10-12-2011 04:02 PM

Thanks for the reply and welcome. I’m in the middle of two medium sized projects(Doesn’t everyone do it that way?) although feel the Bosch will be sitting in my shop in a very short time. Every machine I have is mobile and the Bosch should fit in well. Anyone in the market for a Jet Contractor Saw??

-- Retrowood

View PurpLev's profile

PurpLev

8476 posts in 2397 days


#11 posted 10-12-2011 04:03 PM

I’ve had the same saw and did the same under saw cover adjustment which helped a lot.

here is a thought though (and I did the same thing to my current saw and am reverting back to original):

What you want to do is keep the airflow going to pick up the fine dust (mostly) as well as larger chips. If you cover all the openings of air (wheel slot) you are creating a vacuum which is great for picking something up from the floor, but not really that great for keeping air flow running as it stops it. What this might lead to is if you are cutting a dado (non through cut) or if your cut is blocking the saw inserts leading to no incoming air route all the dust will just fall in the saw cabinet and start accumulating there (fine dust and all).

bottom line – I would keep the wheel slot open for fresh air.

just my thoughts and experience YMMV.

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View juicegoose's profile

juicegoose

113 posts in 1811 days


#12 posted 10-12-2011 04:15 PM

Purp, although I agree 100% that airflow should be allowed like you stated, the theory behind leaving such a large opening(the wheel area) is incorrect. At least on the Bosch saw there are air slots at the top of case. More specifically there is some slots on the motor side of the housing. When u restrict the large holes it encourages airflow through these slots. Not only does it help cool the saw but the air turbulence circulates towards the dust collection opening. There was a great article on the fine woodworking website by an engineer that did alot of tests on airflow to get the best circulation/turbulence to get and keep dust moving. Do a search on the website. Personally my saw works much better at collection with all the major holes covered and letting the air flow through the case slots. Like everything else, your results may vary.

View Retrowood's profile

Retrowood

117 posts in 1167 days


#13 posted 10-12-2011 07:19 PM

While I’m no engineer, I tried a couple ideas I’ve read about w/ my Contractor saw. I completely covered the opening at rear around motor w/ perhaps less than a 1% air opening now. I then installed a thin kerf blade and zero-clearance throat plate. Dust was worse, actually blowing right up at my face when operating saw. I then modified the throat plate using a idea from FWW, widening the back 2” of the slot to 1/4” and notching where the blade teeth come up and out at 1” blade setting. Notches are 3/16” of an inch. I also blocked front control slot w/ magnetic cover. Much worse, not in my face although the pile of dust from ripping one 5’ long Sitka Spruce was 2” high on the front of the table. Hmmmm, what is going on here? I’m going to change out the zero-clearance to my original open model next to see if things improve.

-- Retrowood

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PurpLev

8476 posts in 2397 days


#14 posted 10-12-2011 07:34 PM

Thanks for the relpy JuiceGoose – Its been a while since I had the bosch and forgot about the motor cooling slots in the saw housing – that WILL work well as long as there is enough air allowance to get into the cabinet so in your case covering the wheel might be a good idea. for other saws – probably not so much.

Enjoy making sucked dust!

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View Dennisgrosen's profile

Dennisgrosen

10850 posts in 1864 days


#15 posted 10-12-2011 10:45 PM

thank´s for sharing this
not that I have or have planes of buying a Ts at the moment
but I do have this little bosch on very short list of electronkiller device´s I want if
I get the chance of building my own house with a big shop …. :-)

take care
Dennis

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