Insert modification for better table DC - Router Forums
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post #1 of 28 (permalink) Old 03-11-2020, 08:59 AM Thread Starter
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Default Insert modification for better table DC

Hi folks,

This is my first post. Iím sharing my router insert mod for feedback and suggestions.

Background: Iíve been working on a router table setup that includes a PC 7518 in a Jessem lift, an Incra Ls Positioner, and the Incra Wonderfence. I plan to build the table with a DC box under the router. I have researched other great threads for that.

I ran into a snag where the Jessem inserts have no DC suction holes like the desired Incra magnaloc inserts do for e.g. -for plowing dados away from the fence DC.

Solution: While I could invest in an Incra adapter plate and cleansweep inserts I decided to modify the Jessem inserts and add my own holes. Iíve attached pictures of the mod. I figure the holes should be adequate to capture dust during dadoing away from the fence DC. I home the material going by bit doesnít snag on the hole edges. I sanded flat and removed burrs. As you see in the pics the insert underside has divisions that assisted even placement of Forster bit holes.

Feedback/suggestion?

Best Regards,

Bill
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post #2 of 28 (permalink) Old 03-11-2020, 09:10 AM
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Nice solution.

The more I do, the less I accomplish.
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post #3 of 28 (permalink) Old 03-11-2020, 09:42 AM
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Someone told us a few years ago that he drilled holes like that in his table saw insert and it improved the DC on it too. Good job.
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post #4 of 28 (permalink) Old 03-11-2020, 12:14 PM
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That does allow air to flow through the plate, but a router has a fan on the bottom blowing air through the motor for cooling.
That means the dust will be blown UPWARDS onto the surface of the table by these vents, so you need good extraction at the fence.

I have the incra perforated plates and its very interesting watching the dust billow up out of the table.
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post #5 of 28 (permalink) Old 03-11-2020, 02:36 PM Thread Starter
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Thanks for your thoughts Bob,

However, the vented Incra plates are designed to support downward suction of dust into Incra’s cleansweep box below, containing the router and having a 4” DC connection. My set up would have a 2 hp cyclone DC attached. YT videos show dadoing away from the fence with little dust on the table and all dust being sucked through the box under the table. My box will be DIY.

At the same time I have been somewhat concerned about dust going downward and maybe getting into the router. It does seem to be accepted practice not to worry about it.

Best Regards
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post #6 of 28 (permalink) Old 03-11-2020, 03:02 PM
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They might well be designed to allow dust downwards, but thats not what happens on my table.

My router is enclosed, but since fitting the incra plate and cleansweep inserts, there is no reason to have the extraction on the box. I suspect 90% of the dust is pushed upwards into the fence extraction during a side cut. Obviously more is held down by the wood if you are grooving from below.

I dont know for sure, but I think all routers have cooling fans. My makita creates quite an updraught when in the table. I have no worries of dust falling into the bearings
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post #7 of 28 (permalink) Old 03-11-2020, 03:10 PM
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I like you idea and execution...

This would have been the week that I'd have finished chewing thru the restraints...
If only new layers hadn't been added....

Stick....
Forget the primal scream, just ROAR!!!
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post #8 of 28 (permalink) Old 03-12-2020, 08:17 AM
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Quote:
Originally Posted by sunnybob View Post
They might well be designed to allow dust downwards, but thats not what happens on my table.

My router is enclosed, but since fitting the incra plate and cleansweep inserts, there is no reason to have the extraction on the box. I suspect 90% of the dust is pushed upwards into the fence extraction during a side cut. Obviously more is held down by the wood if you are grooving from below.

I dont know for sure, but I think all routers have cooling fans. My makita creates quite an updraught when in the table. I have no worries of dust falling into the bearings
Bob just wondering if you have a DC box around the router and if so does it have holes to allow air to be pulled in and through the box. When I built my router table I used plexiglass on the door front and drilled 5 - 1-1/2" holes for air to come into the space and the compartment has a 4" connector that connects to the DC system along with a 2-1/2" connection on the fence. The solution that Bill is using will allow better collection on my system after I drill those holes. And my system works great now but will be improved with this mod on some cuts while not adding much on others. It's the some part that can make a mess for me.
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post #9 of 28 (permalink) Old 03-12-2020, 08:52 AM
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My system has evolved over the last 5 years (lol).
When I built the enclosure, I cut a 4" diameter hole directly under the router, and connected the router to the hole with flexible hose so the router fan was pulling clean air through and up the motor. There is another 4" hole in the back of the cabinet for the dust extraction, and 4 x 1" holes in the front of the cabinet to allow replacement air in.
This worked well.

Since fitting the incra clean sweep system (replacing the Kreg plate that warped) I noticed how much was being blown upwards. As an experiment i disconnected the extraction hose from the cabinet. I do have good extraction on the fence though.
Any side or shape cutting and it all goes through the fence. Obviously if i am cutting an upside down groove (rebate, rabbit, whatever you want to call it), then some dust gets forced down into the box which needs vacuuming out one way or another, but the router is always sucking clean air through the bottom of the box.
This is with my Makita RP1800, which has been in the table from new almost 6 years ago now. I cant comment on any other make of router's fan efficiency
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post #10 of 28 (permalink) Old 03-12-2020, 08:53 AM
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My system has evolved over the last 5 years (lol).
When I built the enclosure, I cut a 4" diameter hole directly under the router, and connected the router to the hole with flexible hose so the router fan was pulling clean air through and up the motor. There is another 4" hole in the back of the cabinet for the dust extraction, and 4 x 1" holes in the front of the cabinet to allow replacement air in.
This worked well.

Since fitting the incra clean sweep system (replacing the Kreg plate that warped) I noticed how much was being blown upwards. As an experiment i disconnected the extraction hose from the cabinet. I do have good extraction on the fence though.
Any side or shape cutting and it all goes through the fence. Obviously if i am cutting an upside down groove (rebate, rabbit, whatever you want to call it), then some dust gets forced down into the box which needs vacuuming out one way or another, but the router is always sucking clean air through the bottom of the box.
This is with my Makita RP1800, which has been in the table from new almost 6 years ago now. I cant comment on any other make of router's fan efficiency
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