![\"DeWalt](\"https:\/\/i0.wp.com\/3d.rayharwood.com\/wp-content\/uploads\/2015\/06\/20150617_150657031_iOS.jpg\")
<\/a>DeWalt sander with included dust catcher accessory<\/p><\/div>\n
I’ve been working on a three tiered plant stand for the back yard, made from mostly 2×4 lumber.\u00a0 Wanting to stain the finished item, I’ve been sanding each piece before assembly with my DeWalt orbital sander.\u00a0 While the sander comes with a nice dust catcher, the instructions mention being able to push your shop vac hose onto the output nozzle and reduce the overall amount of dust that escapes from the sanding process.<\/p>\n
My shop vac hose will “fit”, but only loosely, and after some experimentation yesterday, determined it would fall off within a couple of minutes.<\/p>\n
What other option did I have, but to design and print an adapter!<\/p>\n
Measurements<\/h1>\n![\"Measurements](\"https:\/\/i2.wp.com\/3d.rayharwood.com\/wp-content\/uploads\/2015\/06\/20150617_140859422_iOS.jpg?resize=225%2C300\")
<\/a>Measurements for shop vac to sander adapter<\/p><\/div>\n
Out to the garage with my caliper, pen, and paper I went. Since the nozzle has several inner fittings, I took all the measurements I thought I’d need.\u00a0 <\/p>\n
It’s possible to push the actual shop vac hose directly onto the adapter I’m about to make, but there’s also a small “tool adapter” that came with the shop vac, so I took measurements of both.<\/p>\n
Several possible configurations<\/h1>\n
![\"Sander](\"https:\/\/i0.wp.com\/3d.rayharwood.com\/wp-content\/uploads\/2015\/06\/20150617_151040625_iOS.jpg?resize=300%2C225\")
<\/a>Sander dust nozzle (left), shop vac hose (top right), and included shop vac tool adapter (bottom right)<\/p><\/div>
\nYou might be able to see here that neither the hose nor the included tool adapter will fit snugly on any of the concentric dust nozzle “ports”. <\/p>\n
My initial thought was to fit one end of my adapter to the largest ring of the dust nozzle, and push the shop vac hose onto the other end of the adapter… and forget about the shop vac’s included tool adapter.<\/p>\n
Design<\/h1>\n
![\"Screen](\"https:\/\/i1.wp.com\/3d.rayharwood.com\/wp-content\/uploads\/2015\/06\/Sander-ShopVac-Adapter-FreeCAD1.gif?resize=300%2C225\")
<\/a>Screen shot of FreeCAD design of Sander-to-Shop Vac accessory<\/p><\/div>
\nI dashed back into the house, where I fired up FreeCAD and fashioned the cylinders to go around the outermost dust nozzle ring (green in the FreeCAD screen shot). <\/p>\n
Next I made the cylinders on which to attach the shop vac hose, offsetting it about 30mm from the other end (blue in the FreeCAD screen shot). <\/p>\n
Lastly, I made the cones to adapt the sander-end ring to the shop-vac-end ring (orange in the FreeCAD screen shot).<\/p>\n
Print<\/h1>\n
![\"Printing](\"https:\/\/i1.wp.com\/3d.rayharwood.com\/wp-content\/uploads\/2015\/06\/20150617_140827346_iOS.jpg?resize=300%2C300\")
<\/a>Printing the sander-to-shop vac accessory on my Lulzbot TAZ 4 printer, about half way through.<\/p><\/div>
\nI exported the design into an STL file, which I then ran through Slic3r, using Lulzbot’s provided configuration for fast PLA with a 0.28mm layer thickness, and no support.<\/p>\n
I imported the gcode file into Printerface, which estimated2423mm of filament and 1 hour and 3 minutes duration. I fired up the extruder and bed temperatures (200C for the extruder, 70C for the bed), and started the print.<\/p>\n
An hour and 5 minutes later, it was a real part!<\/p>\n
The part<\/h1>\n
![\"Hot](\"https:\/\/i0.wp.com\/3d.rayharwood.com\/wp-content\/uploads\/2015\/06\/20150617_151057894_iOS.jpg?resize=300%2C225\")
<\/a>Hot off the printer, and ready to test!<\/p><\/div>
\nHere’s the part, in roughly the same position as in the FreeCAD screen shot above. The left-most ring will fit around the outer-most ring on the sander, and the shop vac hose will fit over the right-most ring.<\/p>\n
It fits!<\/h1>\n
<\/a>Measurements for shop vac to sander adapter<\/p><\/div>\n
Out to the garage with my caliper, pen, and paper I went. Since the nozzle has several inner fittings, I took all the measurements I thought I’d need.\u00a0 <\/p>\n
It’s possible to push the actual shop vac hose directly onto the adapter I’m about to make, but there’s also a small “tool adapter” that came with the shop vac, so I took measurements of both.<\/p>\n
Several possible configurations<\/h1>\n
<\/a>Sander dust nozzle (left), shop vac hose (top right), and included shop vac tool adapter (bottom right)<\/p><\/div>
\nYou might be able to see here that neither the hose nor the included tool adapter will fit snugly on any of the concentric dust nozzle “ports”. <\/p>\n
My initial thought was to fit one end of my adapter to the largest ring of the dust nozzle, and push the shop vac hose onto the other end of the adapter… and forget about the shop vac’s included tool adapter.<\/p>\n
Design<\/h1>\n
<\/a>Screen shot of FreeCAD design of Sander-to-Shop Vac accessory<\/p><\/div>
\nI dashed back into the house, where I fired up FreeCAD and fashioned the cylinders to go around the outermost dust nozzle ring (green in the FreeCAD screen shot). <\/p>\n
Next I made the cylinders on which to attach the shop vac hose, offsetting it about 30mm from the other end (blue in the FreeCAD screen shot). <\/p>\n
Lastly, I made the cones to adapt the sander-end ring to the shop-vac-end ring (orange in the FreeCAD screen shot).<\/p>\n
Print<\/h1>\n
<\/a>Printing the sander-to-shop vac accessory on my Lulzbot TAZ 4 printer, about half way through.<\/p><\/div>
\nI exported the design into an STL file, which I then ran through Slic3r, using Lulzbot’s provided configuration for fast PLA with a 0.28mm layer thickness, and no support.<\/p>\n
I imported the gcode file into Printerface, which estimated2423mm of filament and 1 hour and 3 minutes duration. I fired up the extruder and bed temperatures (200C for the extruder, 70C for the bed), and started the print.<\/p>\n
An hour and 5 minutes later, it was a real part!<\/p>\n
The part<\/h1>\n
<\/a>Hot off the printer, and ready to test!<\/p><\/div>
\nHere’s the part, in roughly the same position as in the FreeCAD screen shot above. The left-most ring will fit around the outer-most ring on the sander, and the shop vac hose will fit over the right-most ring.<\/p>\n