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Dewalt DW735 Planer Bed Collecting Chips

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Forum topic by Nevaskwehr posted 03-19-2018 12:44 PM 1353 views 0 times favorited 19 replies Add to Favorites Watch
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Nevaskwehr

14 posts in 39 days


03-19-2018 12:44 PM

Topic tags/keywords: planer dewalt dw735 dw734 power tools fixes issues wood chips help

Hi All,

This is my first post here, and on any wood working forum. I’m new to owning my own tools, and recently bought a DW735 secondhand. It seemed to have been well-cared for, and I built a rolling stand for it based on John Heisz’s Design, with the exhaust shooting into a trash can underneath the table top. I cut out a hole behind the outfeed to allow for air to escape the trash can, which currently just has a screen that is clamped down over it, as the melamine board I bought for the long indeed/outfeed/bed was not flat and I have not gotten around to making a better solution.

Four or five passes through the planer and I managed to rack the thing, which I was able to fix by removing the top and manually turning each post until each corner reached the top and it returned to flat, following a fix I found here, I believe. After that, all was well and I planed board after board until I realized that I beat up the blades by getting too eager. So, I turned the blades over to reveal fresh edges, and started again.

Soon after, I attempted making a sled to run small stock, and put down some rug non-slip material on an MDF board. I placed small boards on top, and shimmed them to be stable, then ran it through. I had forgotten about the fan, so I forgot to glue down the non-slip. I’m sure you know what happened next. A bunch of bad, bad noises as the planer sucked up and chewed on the non slip. Ugh.

This brings us to today. I’m trying to plane some hard maple, and the planer is not only spitting out a bunch of chips onto the bed, but it’s making a very slight rattle sound. Very slight, but there. On top of this, I notice parallel scratches in the steel spanning the length of the bed, just deep enough that I can feel them.

I took off the top again to see if the fan housing is broken, and it’s not. Everything looks normal under the hood. Any guesses as to what the problem could be? And how to get the scratches out? I’m really hoping there’s a fix, even if it’s replacing a part. I just really don’t want to send it for repair, as the closest service center is in Anaheim, CA (about 1-2 hours away) and it has horrible reviews, not to mention the potential cost.

I know people say that making mistakes is how we learn, but right now I’m just feeling dumb and frustrated. I just want to get working again! If you’re still reading, thank you for putting up with my ignorance. ????

-- If I knew what I was doing, I’d be rich by now


19 replies so far

View msinc's profile

msinc

351 posts in 473 days


#1 posted 03-19-2018 01:07 PM

I would suggest you have a good careful look at the cutter head. Pay particular attention to the bolts that hold the blades in place. One of them may have come loose or even got out. I would also suggest that you make sure the chip discharge port, which has its own separate little motor, is also clear in its entirety. The 735 is a nice little planer, but it is touchy about these two areas. Also, if one of the knife retaining bolts is by chance missing or damaged you should be aware that you cannot substitute them for common hex head bolts. What is in there should be a pan head with an “Allen” or Torx type head and a typical, easy to find hex head type wont clear.

View johnstoneb's profile

johnstoneb

2872 posts in 2142 days


#2 posted 03-19-2018 01:57 PM

You’ve at a minimum plugged the exhaust fan up and may have wrecked the impeller on the exhaust fan.

-- Bruce, Boise, ID

View gwilki's profile

gwilki

196 posts in 1443 days


#3 posted 03-19-2018 02:07 PM

As msinc said, remove the exhaust port shroud and see if the exhaust area is plugged or/and if the impeller has broken vanes. The shroud comes off easily by unscrewing the 3 long plastic wing nuts and turning the shroud so that it will pull clear of the housing.

When you say that you have scratches on the metal, do you mean the bed of the planer? If so, you can sand them out with fine, wet paper. The scratches won’t do any harm, but the chances are that, when you made the scratches, the edges are proud of the bed, so they will gouge the wood. I did the same thing some years ago. I didn’t much like the thin “chrome” bed that came on the planer, so I removed it and replaced it with a piece of 1/8 stainless sheet. That’s overkill, likely, but it sure solved my problem.

-- Grant Wilkinson, Ottawa ON

View ChefHDAN's profile

ChefHDAN

1057 posts in 2819 days


#4 posted 03-19-2018 02:07 PM


Also, if one of the knife retaining bolts is by chance missing or damaged you should be aware that you cannot substitute them for common hex head bolts. What is in there should be a pan head with an “Allen” or Torx type head and a typical, easy to find hex head type wont clear.
- msinc

The older units have the hex head bolts and the newer units will have the torx bolts, you can find a kit to convert the hex heads over to the torx on Amazon for under $20 it has all of the bolts and a new key with the magnets for blade changes. I’ve got my 735 on my DC, and when I forget to open the blast gate I get some chip blowback to the bed, so I have to agree you’ve got a blockage in the line.

-- I've decided 1 mistake is really 2 opportunities to learn.. learn how to fix it... and learn how to not repeat it

View Tony1212's profile

Tony1212

182 posts in 1704 days


#5 posted 03-19-2018 02:19 PM

When I first got my DW735, I tried to come up with a bunch of ways to collect the chips. I quickly realized that if I didn’t give the ejector enough ventilation, I’d get chips on the bed. So that’s my immediate thought on that. Make sure your airways aren’t clogged and are big enough to allow enough air throughput. If it sucked up the non-slip and some of that made it into the ejector, that could be jamming things up. Maybe the rattle you hear is the ejector fan hitting something?

As for the parallel scratches on the bed, you mentioned that you made a sled with MDF. Were there any screws used in that sled? I’m thinking that when things went bad with the non-slip, something got jammed between the rollers and the work/sled causing the sled to grind against the bed.

I’m not sure I would worry too much about the scratches unless they are leaving marks on the work. If you think they might be affecting the feed rollers, then maybe use some fine grit wet/dry sandpaper to take down any protrusions.

-- Tony, SW Chicago Suburbs

View msinc's profile

msinc

351 posts in 473 days


#6 posted 03-19-2018 03:56 PM

Also, if one of the knife retaining bolts is by chance missing or damaged you should be aware that you cannot substitute them for common hex head bolts. What is in there should be a pan head with an “Allen” or Torx type head and a typical, easy to find hex head type wont clear.
- msinc

The older units have the hex head bolts and the newer units will have the torx bolts, you can find a kit to convert the hex heads over to the torx on Amazon for under $20 it has all of the bolts and a new key with the magnets for blade changes. I ve got my 735 on my DC, and when I forget to open the blast gate I get some chip blowback to the bed, so I have to agree you ve got a blockage in the line.

- ChefHDAN

That’s interesting…so they made an earlier version of the 735 with hex head bolts? Something else {maybe the cutter head itself} must be different. Mine is the latter version and I had a button head torx come out of mine once and I tried to just replace it with a hex, but it didn’t work. It hangs out too far and gunches into the wood when I tried to run it. How the loose screw never damaged the exhaust fan motor is beyond me, it sure did make a lot of noise until I got it out of there.

View Nevaskwehr's profile

Nevaskwehr

14 posts in 39 days


#7 posted 03-19-2018 04:55 PM


I would suggest you have a good careful look at the cutter head. Pay particular attention to the bolts that hold the blades in place. One of them may have come loose or even got out. I would also suggest that you make sure the chip discharge port, which has its own separate little motor, is also clear in its entirety. The 735 is a nice little planer, but it is touchy about these two areas. Also, if one of the knife retaining bolts is by chance missing or damaged you should be aware that you cannot substitute them for common hex head bolts. What is in there should be a pan head with an “Allen” or Torx type head and a typical, easy to find hex head type wont clear.

- msinc

Thank you, I’m still learning about this planer. I noticed that one of the bolts was missing in the middle of one of the blades when i had first opened it up to flip them, but I figured there were enough bolts keeping it in place. I will definitely try to find a replacement.


As msinc said, remove the exhaust port shroud and see if the exhaust area is plugged or/and if the impeller has broken vanes. The shroud comes off easily by unscrewing the 3 long plastic wing nuts and turning the shroud so that it will pull clear of the housing.

When you say that you have scratches on the metal, do you mean the bed of the planer? If so, you can sand them out with fine, wet paper. The scratches won t do any harm, but the chances are that, when you made the scratches, the edges are proud of the bed, so they will gouge the wood. I did the same thing some years ago. I didn t much like the thin “chrome” bed that came on the planer, so I removed it and replaced it with a piece of 1/8 stainless sheet. That s overkill, likely, but it sure solved my problem.

- gwilki

I’ve removed the shroud and the fan housing to check the fan, but I hadn’t closely inspected the dust shroud. I’ll check that when I get home.

Yes, they’re in the bed and marking the wood. I was so worried about putting it out of flatif I sanded it, but you think it will be ok?


When I first got my DW735, I tried to come up with a bunch of ways to collect the chips. I quickly realized that if I didn t give the ejector enough ventilation, I d get chips on the bed. So that s my immediate thought on that. Make sure your airways aren t clogged and are big enough to allow enough air throughput. If it sucked up the non-slip and some of that made it into the ejector, that could be jamming things up. Maybe the rattle you hear is the ejector fan hitting something?

As for the parallel scratches on the bed, you mentioned that you made a sled with MDF. Were there any screws used in that sled? I m thinking that when things went bad with the non-slip, something got jammed between the rollers and the work/sled causing the sled to grind against the bed.

I m not sure I would worry too much about the scratches unless they are leaving marks on the work. If you think they might be affecting the feed rollers, then maybe use some fine grit wet/dry sandpaper to take down any protrusions.

- Tony1212

I’ll defini check all of the airways. I’m worried I messed up the ejector, but there was no evident damage.

As for the sled, I did use screws, but I’m baffled because (A) they aren’t sticking proud of the sled and (B) the lines are far too numerous and lengthy to have been caused by that. Is it possible that the ipe I used caused it, being such a dense wood? I didn’t think wood could do that.

Also, if one of the knife retaining bolts is by chance missing or damaged you should be aware that you cannot substitute them for common hex head bolts. What is in there should be a pan head with an “Allen” or Torx type head and a typical, easy to find hex head type wont clear.
- msinc

The older units have the hex head bolts and the newer units will have the torx bolts, you can find a kit to convert the hex heads over to the torx on Amazon for under $20 it has all of the bolts and a new key with the magnets for blade changes. I ve got my 735 on my DC, and when I forget to open the blast gate I get some chip blowback to the bed, so I have to agree you ve got a blockage in the line.

- ChefHDAN

Thanks for the tip! I’ll look that kit up.

Also, if one of the knife retaining bolts is by chance missing or damaged you should be aware that you cannot substitute them for common hex head bolts. What is in there should be a pan head with an “Allen” or Torx type head and a typical, easy to find hex head type wont clear.
- msinc

The older units have the hex head bolts and the newer units will have the torx bolts, you can find a kit to convert the hex heads over to the torx on Amazon for under $20 it has all of the bolts and a new key with the magnets for blade changes. I ve got my 735 on my DC, and when I forget to open the blast gate I get some chip blowback to the bed, so I have to agree you ve got a blockage in the line.

- ChefHDAN

That s interesting…so they made an earlier version of the 735 with hex head bolts? Something else {maybe the cutter head itself} must be different. Mine is the latter version and I had a button head torx come out of mine once and I tried to just replace it with a hex, but it didn t work. It hangs out too far and gunches into the wood when I tried to run it. How the loose screw never damaged the exhaust fan motor is beyond me, it sure did make a lot of noise until I got it out of there.

- msinc

Glad to hear you didn’t get any permanent damage! Makes me feel a little better about my situation.

-- If I knew what I was doing, I’d be rich by now

View jerryminer's profile

jerryminer

918 posts in 1411 days


#8 posted 03-19-2018 06:41 PM

To replace one missing screw on the cutter head, you can steal one from the plastic cap on one of the corner posts. That screw can be replaced with a “standard” metric pan head screw.

-- Jerry, making sawdust professionally since 1976

View pintodeluxe's profile

pintodeluxe

5626 posts in 2783 days


#9 posted 03-19-2018 07:27 PM

Here’s what happened when I discovered a small crack in my fan housing (see link). It looked fine on visual inspection, but once I pulled it out I could see the extent of the damage. Doesn’t take much to break the plastic shroud or fan housing.
http://lumberjocks.com/pintodeluxe/blog/43457

Good luck with it.

-- Willie, Washington "If You Choose Not To Decide, You Still Have Made a Choice" - Rush

View Nevaskwehr's profile

Nevaskwehr

14 posts in 39 days


#10 posted 03-20-2018 12:24 AM

This looks slightly damaged, is it enough to cause the blowback and rattle?

-- If I knew what I was doing, I’d be rich by now

View gwilki's profile

gwilki

196 posts in 1443 days


#11 posted 03-20-2018 01:29 PM

It’s a bit tough to see, but it looks like all the vanes are chewed up, and it may just be the pic and/or my old eyes, but it looks like one vane is missing. If not, forget I mentioned it. If I were you, I would replace it

As for the scratches in the bed, mine were definitely caused by rough wood, no screws. I did sand the bed smooth and all was well. I just didn’t like the look of it, so I replaced it with a better alternative.

-- Grant Wilkinson, Ottawa ON

View Nevaskwehr's profile

Nevaskwehr

14 posts in 39 days


#12 posted 03-20-2018 02:33 PM


It s a bit tough to see, but it looks like all the vanes are chewed up, and it may just be the pic and/or my old eyes, but it looks like one vane is missing. If not, forget I mentioned it. If I were you, I would replace it

As for the scratches in the bed, mine were definitely caused by rough wood, no screws. I did sand the bed smooth and all was well. I just didn t like the look of it, so I replaced it with a better alternative.

- gwilki

None are missing, but the all seem to have had a bit of the plastic shaved off towards the bolt. I’ll replace it, and the missing bolt, and see what happens. Any bets on where to get replacement parts besides eRaplacementparts.com?

-- If I knew what I was doing, I’d be rich by now

View GR8HUNTER's profile

GR8HUNTER

3661 posts in 682 days


#13 posted 03-20-2018 02:46 PM

why dont you want to use ereplacementparts ? :<))

-- Tony Reinholds,Pa. REMEMBER TO ALWAYS HAVE FUN

View ChefHDAN's profile

ChefHDAN

1057 posts in 2819 days


#14 posted 03-20-2018 03:26 PM

If I needed to plane ipe I’d be reaching for a hand plane, I’d be very scared to risk my blades with that, or if there was no other way I’d try to cut a 64th at a time.

-- I've decided 1 mistake is really 2 opportunities to learn.. learn how to fix it... and learn how to not repeat it

View Nevaskwehr's profile

Nevaskwehr

14 posts in 39 days


#15 posted 03-20-2018 03:34 PM

Is it the best place to get parts? I’ve never had to do it.

-- If I knew what I was doing, I’d be rich by now

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