I was watching one of Marcs videos the other day and he was using his chop saw to cut the end off of a board. The video was a very tight shot of the saw, I assume it’s a Festol. What I saw was that his saw had a factory rubber “boot” of sorts that was behind the blade used to direct the dust up and into the waiting dust extraction system. The rubber was soft enough to easily bend and yet had a memory to it so that it returned to it’s normal self.
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We use rubber sheeting at work when we need to protect power wires that may rub against something and damage the outer insulation. So I asked one of the electricians if he would cut me off a small square.
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The square ended up being about 9”. I didn’t measure the thickness of the rubber but its in ballpark of 3/16” or so. I used some double sticky back tape to hold it in place while I figured things out. I then drilled and added 4 1/8” rivets to hold it in place permanently. It looks a bit cobbled together but it works quite well. Without the rubber, I doubt that the vac picked up any of the dust. If it did, it was minimal. It still doesn’t get 100% of the dust but it is an improvement on the order of 1,000nds times better than it was.
Maybe you can do something like this if you have the same problems that I do with dust collection on chop saw / CSMS / et. al.
Chunk