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Dust boot was my first project on the cnc like most probably. Mine is made from less fancy materials .75" Russian birch. Few questions.

1.Do you know the specs on the bristles ? I used 3" .030" diameter and they are a tad stiff.

2. Do you like the Rockler pistol grip thing? Im assuming the curved claw attachment is a rockler item too? Im will check it out. Im looking to add something like that.

I run 2 lines. 1 line to the dust boot and one loose for general clean up on the table both are wide open all the time. My 3hp DC will get real hot if I restrict it. Currently I have a single 4" from the dust boot reduced down to a 6" but I have been thinking of doing a new twin 4" from the boot to just above the spindle then wye'd to a single 6" flex but thats means I would have to buy a 6" swivel and those things arnt cheap. The 4" ones comes in plastic version for 30 bucks or so but the 6" is only available in metal version and is more like $400.

I too have headroom issues and found the swivel helps and cuts down on the amount of flex needed. That stuff is a serious CFM killer. I try to minimize it as much as possible. I only have about 4' of it when stretched in the whole setub for a 4x8 router.

Im also thinking if the dust boot was on some small linear rails and a lead/ballscrew so you could turn a small hand crank to adjust the height of the dust boot independent of the spindle. I have some small slots where mine attaches that offers about an 1.5" of height adjustment which is typically enough but on the fly adjustments by turning a handle would be cool

One tip, is I would try and tie the boot back to the main Z carriage and not clamp to the actual spindle. It looks to have a considerable amount of weight cantilevered off to the side. If that decides to pop off mid cut things could get sketchy fast. Also minimize or eliminate the flex everywhere and avoid reducers especially in areas like from the blower to the baffle Thats a big choke point right out of the gate.
 

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I like the ingenuity of using the broom bristles... Here is a pic of mine when I first started putting it together. I ended up slotting the bracket where it attaches to the Z later (not pictured here) Here are my likes/dislikes of this design.

Likes
1. solid as a rock, this thing aint moving or coming off no matter what.
2. does a "good" at dust collecting.
3. Mag. shoe makes for quick easy bit change
4. dense bristles do good at containing dust
5. Height adjustable

Dislikes
1. Bristles seem a little stiff would probably go with .020 next time. These are mcmaster carr item btw.
2. My biggest issue is the single 4" port. when Im cutting near the Y0 area it hangs past the end of the table and does very little dust collecting so it ends up all over the floor. Im thinking twin tubes one on either side would work much better this way if or when cutting at the far ends of the X axis at least one of the tubes would still be sucking.
3. Its bulky, the 4" diameter takes up a lot of space would be even better with oval for a more compact closer to the bit collection area
4. Would like on the fly height adjustment like a manual knob that could raise or lower the whole thing a few inches(this is not a necessity but would be nice
Wood Automotive tire Engineering Gas Machine
 

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After a quick google search I found this. Its pretty much what I was thinking minus the on the fly height adjustment, which I can deal with especially if the bristles are a little more flexible than mine. This thing is pretty sweet looking but I dont have a 3d printer. If I had an Avid machine I would be all over this thing. I reached out to the seller to see if he would work with me to make one for my specifications.
Bumper Machine tool Office equipment Gas Composite material
 

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This thread has made me pursue upgrading my dust shoe sooner than anticipated. I have been in contact with Keith the maker of the dust shoe pictured above. He already has the dust shoe designed for many different machine spindle combinations big and smaller machines and if he doesnt already have it he will customize one for you. He is currently working on designing one for my machine. He's a 5 star seller on Etsy and so far has been great to work with. Im suuuuuuper excited to get this thing and test it out. His prices are very reasonable too. Im getting one similar to the one pictured with a 6" port. I use a 3hp laguna cyclone and I think the 4" line is choking it off to much and making the DC work to hard. I had to add an additional 4 in port that stays open all the time because without it my motor would overheat. Either way I will post more photos and experience after I receive it. I have no connection to Keith but just wanted to make others are aware of what looks like a great product and seller. More to come.

Link to his Etsy store
 
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