Dust Shoe

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Dust Shoe

Postby SPH01 » Sun Feb 10, 2013 12:14 pm

I decided to make a dust shoe for the spindle rather than buy another one. I chose a 2-1/2" for this one rather than running the 5hp shop dust collector for 10+hours.
If you have any improvement ideas I'm open to updating it
Thanks Steve
80mm Dust Shoe.pdf
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Re: Dust Shoe

Postby Wolffie1 » Sun Feb 10, 2013 3:47 pm

Thank you for the files.
I am just remaking my HD in all aluminium with an 80mm watercooled spindle :D
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Re: Dust Shoe

Postby 4DThinker » Sun Feb 10, 2013 6:35 pm

I've been working on a dust shoe design that would step the hose input over to the bit/collet zone, then use a short section of 3" spring hose to surround the bit and simply compress as needed when the bit dives into a board. I like the ease of magnets for holding it on and releasing it easily, so my idea would use the same top piece that comes from Rockler, and perhaps include a way to slip the surround hose up and down some as bit lengths change.

So far I'm very disappointed with the brush version.
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Re: Dust Shoe

Postby SPH01 » Sun Feb 10, 2013 7:59 pm

I've been using the KentCNC dust shoe on my HD for over a year. It's a 4" hose and it gets over 95% of the dust I create. That's a 70% better than my table saw does with an overhead arm and a lower dust port. The water cooled spindle has no air out the bottom to blow the dust away so the shoe gets 99% of it. I"m not certain that the bearing issues I had on the routers weren't caused by the dust collector pulling cooling air out of the router. I have seen a design that brings in outside air to the router and seals off the dust from the bottom of the router with another 1/2" plate. I think if I was to stay with routers I would look into that design.
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Re: Dust Shoe

Postby fred1030 » Sat Mar 09, 2013 5:45 pm

You forgot to mention what machine you made the dust cover for. I was in such a hurry to make mine that like an idiot I did not masure my router. I have a shark with the colt router.
I did take your file and change the size to fit the colt router. I can't imagine having a dust cover that you can't actually watch the bit cut the wood.
Thank you for your design even though I screwed it up by not double checking my router size. I can't wait now until I go back into town and get another piece of acrylic. I don't know why Rockler sells the black dust cover, half of the enjoyment of cutting something is watching the machine do it's work.
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Re: Dust Shoe

Postby steveohm33 » Sun Nov 24, 2013 2:05 pm

Ah dang, /i wish I would have read Fred1030'a post before I did the same thing. I also have the CNC Shark with the Colt router. Although now I can't see how this would fit into place even with the right size hole. The nuts/bolt ends that hold in the existing tension clamp (that holds the router in place) extend nearly 3/4" below, so the acrylic doesn't seem like it could push up flush to the underside. (unless maybe you're supposed to flip the bolts around, and then maybe make countersink holes where the bolt heads exist? or do the bolts go through the top of the shoe?)

Also, are you still able to access the red spindle lock level on the underside of the router when the shoe is in place?

Has anyone had luck with this design on an older CNC Shark with the COlt router? Anyone have pics to share?

Looks like a great design otherwise! Thanks for sharing!

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Re: Dust Shoe

Postby milo30 » Sun Nov 24, 2013 4:08 pm

I haven't looked at the file yet and have the black boot now. Has anyone given any thought to making a notch in the tear to allow you to put it on without raising the gantry? I find too many times I forget until I am zeroed and about to run the file that I forgot to use the boot so I just run without it.
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Re: Dust Shoe

Postby SPH01 » Sun Nov 24, 2013 10:26 pm

I made this for a 80mm spindle not a router. You should be able to change the inside cut and make it fit anything. I went thru three routers and gave up.
the water cooled spindle is about 90% quieter and runs 24/7 with no issues. I don't understand why Rockler is making theirs out of black HDPE, Not being able to see what's happening is asking for trouble.
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Re: Dust Shoe

Postby rungemach » Tue Nov 26, 2013 8:13 am


Excellent job on the dust shoe, and especially the posting of the documentation and parts list.

I have been using the Kent shoes with good success and I like the 4 inch hose capacity. When paired with something like a 1 - 2 hp dust collector, it does a great job. I can see why you do not want to run a full 5hp just for the Shark over long runs.

Initially, NWA warned against using dust collectors on the non-hd sharks due to gantry deflection issues. Now they sell an adapter for it, so I am confused on their position on this. The 4 inch highly flexible hose that Rockler sells is great for dust collection as it is springy, and you can set it up to be weight neutral. I don't know of any small hoses that can do that.

I agree completely on the benefit of the clear material, and have fitted my shoes with led lights inside the shoe, and that helps visibility a lot also.

Also agree on the benefit of the spindle, nice and quiet, with no brushes to wear out

For folks with the non-HD machines which would not fit up a spindle without modifications, It is possible to make a nice custom shoe for the smaller non-hd models, if you make the top piece of the two piece shoe as a replacement piece for the existing z axis part that holds the router clamp. That new replacement piece holds the router clamp, the hose connection, and the magnets. It does not need to follow the outer contour of the brush holder part (it could be smaller around the router end) . The removable brush section also serves as sealing the top off by having only the router hole, the hose, and the space between them open in an otherwise solid top piece that could also have recesses cut in it to fit up snug around the z axis side plates that extend below the new router/hose mount plate. I'm sorry I don't have any pictures handy. This allows full access to the router and bit change button as the lower router mount plate is replaced by the new plate which is also the hose and magnet holding plate.. When the "brush plate" is removed , the router bottom is exposed as normal. Actually, no reason why you could not do the same on the HD versions. Basically, you replace the router mount plate with a new enlarged one that holds the hose connection and magnets. Feel free to use that design for non-commercial use. If there is any interest I'll see if I can find my old files on this.
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Re: Dust Shoe

Postby bigdon » Sat Jan 11, 2014 5:16 pm

Really nicely designed dust shoe. Looks like you did a good job.

Do you know if anyone has converter this design for a 3.5" diameter spindle? Looking a 690 Porter Cable motor.
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