After purchasing a Lead 1010 CNC Machine, I decided to keep it inside. Unfortunately it became immediately apparent to my wife that I had a major dust problem, and she promply moved out and filed for divorce. After spending all my time on this boot, she left her dust-free palace and moved back in...so, yeah, you probably should put a dust boot on your CNC machine.
- Machine Time:
- ~35 minutes (~30 minutes for main part, ~5 minutes to face)
- Bit or Laser Size:
- 1/8th Inch 4 Flute (.5 inch length flutes) Endmill
- Feeds & Speeds:
- 60 inches per minute, speed is "1" on the DWP611, which is 16000 RPM
- Poplar or Pine
There are 3D printed variants that probably would have been easier to make, that is, if you HAVE a 3D printer, but come on, do you really want to commit that blasphemy ... using a 3D printer for your CNC machine parts?
This was my first CNC project, what better way to jump into Fusion 360 and learn my new machine? With the work done, the next generation noobs will have to find another project to learn on, this project should work without much effort other than downloading and milling. Note that this product is 100% organic, contains no GMOs, and is Gluten Free. I can't say that no animals were hurt during the production of this dust boot.
Note that I have the original cutting area of ~30.5 inches on the Y axis, but with the boot on am reduced to approximately 27 inches on the X axis.
- Version 1: I imported this version into Fusion 360 and rebuilt it from a sketch. I used all the original measurements from Inventables Easle, which was a giant pain to transfer, manually measuring and extruding the project to conform to the original design. I was (am?) a complete NOOB with Fusion 360, so this proecess took 2 weeks of no-wife, no-sleep, TORTURE to figure out... Regardless, once completed the version I had in my hands had tolerances that were too tight.
- The hole for the spindle nut was too small, and I didn't like the smaller size of the shop vac flange hole. Lastly, the light holes were milled in material that was shorter than the surrounding material, allowing for DWP611 airflow from the lights down into the dust boot.
- Here is the site I found the original (version 1) design on. I didn't immediatly notice a place to buy the author a beer, but he does deserve all credit for this awesome design concept: https://www.inventables.com/projects/dewalt-611-air-diverter-and-dust-shoes
- Version 2: I made the spindle hole bigger, the shop vac hole bigger, reshaped the light holes, and kept the spindle hole material the lights are cut into taller.
- Version 2 has a second operation in the project, the facing of the back of the board to cut it from the stock.
- Home Depot:
- Shop Vac Adapters: RIDGID Hose Diameter Adapter Kit for Wet/Dry Vacs (3-Piece)-VT1755 - The Home Depot
- Shop Vac Flange: RIDGID 2-1/2 in. Power Tool Adaptor Accessory for RIDGID Wet/Dry Vacs-VT1407 - The Home Depot
- M8 x 20mm Screws: Everbilt M8-1.25 x 20 mm Plain Steel Metric Socket Cap Screw-803398 - The Home Depot
- M8 Flat Nuts: Everbilt M8-1.25 Zinc-Plated Steel T-Nut (2-Piece per Bag)-803828 - The Home Depot
- 1 x 8 (.75 in tall x 8 in wide x 12 in long) Poplar Board: Poplar Board (Common: 1 in. x 8 in. x R/L; Actual: 0.75 in. x 7.25 in. x R/L)-21070 - The Home Depot
- Amazon CNC Dust Brush, 70mm: https://www.amazon.com/Cleaner-Coll...qid=1549254881&sr=8-6&keywords=cnc+dust+brush
- Version 1:
- GRBL File (for milling): https://openbuilds.com/attachments/dust-boot-v1-nc.37828/
- Fusion 360 Project (for editing): https://openbuilds.com/attachments/dust-boot-v1-f3d.37829/
- Version 2:
- GRBL File, part generation: https://openbuilds.com/attachments/dust-boot-v2-nc.37826/
- GRBL File, facing operation: https://openbuilds.com/attachments/dust-boot-facing-nc.37830/
- Fusion 360 Project: https://openbuilds.com/attachments/dust-boot-v2-f3d.37827/
Before the dust boot, freshly cleand CNC completely dirty from cutting on the dust boot project (boo!):
After the dust boot; I milled the "hello world" project then took this picture. No cleaning happend in or around the CNC machine before this picture was taken (or did it?...you'll have to just take my word on that one):
Final Product: note the use of the brush skirt with viewing window
Dust boot in operation on the "hello world" cut. **Note that I DO NOT recommend the foam skirt as shown, instead use the above listed "brush" style skirt. The foam version had to be babysat to preclude it slipping inside the boot. A redesign could aleviate this issue, but better to just use the brush. Note that I experimented with Home Depot purchased bottom-of-door brush seal options, but found them difficult to shape and not worth the effort, especially since the Amazon version is so easy to use. For best results attach the brush to the boot with velcro. I plan to add a "plexiglass window" into the brushes, but haven't done so yet. Pictures of the brush skirt will follow shortly...
Version 1 (left) and Version 2 (right) side-by-side: **Note, I used a less-effective bit for this project. It has flutes that are too short (.5 inches) and therefore left a center ridge as noted in the below pics (look at the inside edges of the circles, already sanded off the outside edges). If light sanding isn't in your job description, use a bit with longer flutes. Also, I was still designing Version 2 in Fusion 360 when I milled Version 2, which is why if you look closely you will see that the top light hole is too thin. This will not be the case for anybody that prints Version 2 from the provided files (..the experience was uniquely mine, as is the unique character MY dust-boot has).
Version 1 tolerances, note how close the spindle nut is to the edge of the boot (too tight for me):
Version 2 tolerances:
DWP611 disassembled and ready to recieve the dust boot:
The screws for assembly:
Facing the back of the boot:
Final Product: velcro attachment, just use double sided velcro. Note that the black flange protrudes through the bottom of the boot by approximately one inch; this makes tool changes a bit painful, so I would recommend trimming the flange to accommodate.
Final Product: alternate view