Dust Buster
(Page 3 of 4)
October/November 2000
by Bill Greene
The leg, brace and skid assembly consists of four legs (each 33 1/2" long), four braces (one for each side, front and rear) and two skids. The front and rear braces are both 24 1/2" long and are permanently attached to the legs with 2 1/2" - long 3/8" lag screws (four per brace), resulting in two pairs of legs and braces. As for the skids, they measure 32 1/2" long and are attached to the bottom ends of each pair of front and rear legs using 3"long, 8d finishing nails.
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Join the legs and side braces with carriage bolts, wing nuts and cap screws so they can be easily dismantled without using a wrench. Attach the legs to their mounting points on the saw table base with removable 4"-long, 1/4" cap screws, wing nuts and flat washers (four per pair of legs). All of the cap screws should be 3/8" in diameter with sleeves. Then angle the ends of the side braces to match the Outward slant of the legs (lengths on the top and bottom surfaces should be 25 3/'4" and 27 1/2", respectively) and attach the side braces to the legs on bolts projecting from the brace supports.
To permanently mount the brace supports on the backs of the legs (one per leg), use two 3 1/'2"-long, 3/16" diameter lag screws for each support. If you cut the braces at an angle to match the outward slope of the legs, their upper and lower edge lengths should be 3" and 4 1/2", respectively. Fit the. supports with two 3 1/2"-long, 3/8"-diameter carriage bolts inserted from behind through holes and sealed with epoxy cement. Mount the side braces by sliding them into place through their 7/16"-diameter, sleeve-lined mounting holes and hold in place with wing nuts and flat washers. The sleeves used to line the mounting holes come from brass shim stock. Simply shape the brass around the appropriate diameter bolts (either 3/16" or 3/8" diameter) and secure their respective holes with epoxy cement. Substitute copper tubing if needed.
The Funnel Dust Collector
With the exception of its outlet spout, the sawdust collector is entirely constructed of wood and shaped to funnel sawdust down into the Shop Vac® beneath the table. The entire unit consists of five pieces and two cleats. Join the four sides - cut from 1/2" plywood - with 2d finishing nails and carpenter's glue and secure parts labeled Al and A2 inside of B1 and B2. Pieces A1 and A2 should measure 8 3/8" long and angle (at 45°) from a 12 1/2" width at one end to a 1 1/8" width on the other. BI and B2 should measure 8/16" long and angle (at 45°) from a 12 1/2" width to 2 1/2° (see illustration). Attach the cleats - cut from 1x6 pine stock - to the upper outside of B1 and B2. To accommodate your Shop Vac® hose fitting, bore an appropriately sized hole in a 1" plywood plug measuring 2 1/2" square. Be sure to attach the plug to the construction and let the glue dry before boring your hole.
