Thursday, December 8, 2011

Miter Saw Dust Adapter

I have been looking for a vacuum adapter to use with my 10" Craftsman miter saw. Shown below is the miter saw with a home made adapter using a PVC pipe fitting.
Craftsman Miter Saw
Adapter made of 1 1/4 PVC fitting and slip nut.

The adapter is made from a 1 1/4 inch PVC pipe fitting purchased at HD. Three holes have been drilled and tapped around the edge about 1/8" in for 8-32 machine screws. A slip nut which can be found with the sink fittings will hold the hose tightly.

Wednesday, December 7, 2011

Dust Separators

A dust separator, DS, is a device to remove particles from the vacuum air stream without filters. The Dyson vacuum cleaner is an example of this process, using cyclonic airflow for separation. Cyclonic airflow works like a washing machine spin cycle, except instead of throwing water out it throws dust. For this discussion we will examine two devices available to the woodworking shop: The Dust Deputy and the Thein baffle.

To be continued

Miter Saw Cabinet

Basic compound miter saw cabinet without vac.

Well, I have some cabinet grade plywood left from wall cabinet building, so why not a CMS, compound miter saw, cabinet with wings. Here are two designs I found on the web

Since I have a small shop, Mike's smaller design seems best; however, I like the full wings on the other design. The first part of this project will be to build the basic cabinet, a design that could also be used for other tools, such as, the drill press, band saw, etc. The wings will be added later.

  1. Same floor space as present metal stand, 24" x 20".
  2. Two fixed and two locking 3" casters
  3. Draw for tool accessories
  4. Internal duplex power outlet
  5. Extension arms both sides with fence, ruler, and stop.
  6. Removable saw platform to accommodate 10" and 12" fixed and sliding saws
  7. Built in vacuum/dust separator with autoswitch
Note: See post on dust separators

Tool cabinet carcass 
Assembled base cabinet showing casters and draw slide.
View of cabinet top and platform rails.

One of four 1/4" threaded insert for mounting platform.
Electric outlet positioned for use with autoswitch.
Back view showing vac and Sears auto-switch

The drawer design comes from Lowes Creative Ideas, BLOG, woodworking, titled, "Simplified Drawer Construction".

Bill of Materials: Base Cabinet
  1. 2 pieces    20" x 28", sides
  2. 2 pieces    20" x 24", top and bottom
  3. 1 piece     20" x 23 15/16", platform
  4. 1 piece     20" x 3 1/2", top cleat
  5. 1 piece     20" x 5 1/2", bottom cleat
  6. 2 pieces   20" x 1 1/2", platform standoff
  7. 1 piece     24" x 2", front cleat
  8. 4 pieces   4 1/2" x 3", caster plates
  9. 1 piece    5 in x 3 ft poplar 1/2" plank for edging
  10. 2 pieces   22 1/16" x 3 3/4", 1/2" birch plywood, drawer front/back
  11. 2 pieces   16" x 4", 1/2" birch plywood, drawer sides
  12. 1 piece     22 1/2" x 16", 1/4" plywood, draw bottom
  13. 1 piece     4" x 23 3/4", 3/4 plywood, draw front
  14. 100          Kreg 1 1/4" course pocket screws
  15. 1 set        500mm Euro drawer  slide, KV 1284 (Lowes)
  16. 2             3" casters fixed, HF
  17. 2             3" caster, swivel/locking, HF
  18. 4             1/4-20 threaded insert, McMaster 92105A200, ( note 3 )
  19. 1             15 ft extension cord
  20. 1             Electrical box with duplex plate
  21. 1             Duplex outlet
Step by Step Construction of Basic Cabinet
    1. Cut out the sides, bottom, top and cleats, (see note 1)
    2. Drill pocket holes on the underside of the top and bottom pieces
    3. Drill pocket holes in both cleats
    4. Using glue, assemble cabinet carcass, (see note 2)
    5. Glue and clamp front cleat under top at front
    6. Glue caster plates in place
    7. Glue platform standoff to top, see picture
    8. Cut platform to size, round over and sand
    9. Drill 1/4" holes 3/4" in from corners
    10. Place platform in place on standoffs and transfer 1/4" holes to standoff
    11. Drill standoff holes to 21/64", 7/8" deep
    12. Cut 1/2" poplar plank into 3/4" strips
    13. Using glue and brads add poplar strips to front edge of cabinet
    14. Cut 1/2" poplar 24" x 2 3/4" and glue to front cleat.
    15. Sand cabinet and round edges with 1/8" router round over bit.
    16. Seal cabinet with Bullseye Sealcoat
    17. Install 1/4-20 threaded inserts in standoffs, put instant glue on threads first.
    18. Mount casters with 5/16" x 1" lag screws, left side fixed right side swivel
    19. Mount electrical outlet
    20. Mount drawer slides, 4 1/4" below front cleat

    Draw at full extension.

    Step By Step Construction of Drawer
    1. See Lowes Creative Ideas blog, "Simplified Drawer Construction"
    2. Build a drawer using this method, 16" x 23" x 4"
    3. Cut drawer front from 3/4" plywood
    4. Edge drawer front with 1/2" poplar
    5. Sand round and seal
    6. Mount drawer front to drawer, centered left to right with 1/4" lip at bottom
    7. Attach drawer using  #10 x 1" screws from inside drawer

      Step By Step Construction of Wings
      1. To be completed.