I have had my DW735 since 2010, and never had the problem you describe, but I was running a single stage dc so that might be the difference. Now I have the planer hooked to a 5" metal duct system that goes to a Super Dust Deputy and DC that exhausts straight outside, so no filter to overpower. But I can run the planer and watch the exhaust and I can't see any dust so the SDD is doing its job and is not being overpowered. The total duct length is about 33' so maybe that makes a difference. Can you increase the duct length between your planer and DC? My planer has always left a small amount of chips on the bed, but not enough for me to be concerned and want to change anything.
DW 735 Dust Collection
First, read an excellent discussion from this Forum started by MEBCWD about his Dust Separator Comparison.
While he was doing his work, I was confronting a relevant problem in my shop: how to best collect the dust generated by my DeWalt 735 planer. That benchtop planer is excellent (I'm on my 2nd unit after wearing out the 1st), and has an onboard blower that ejects the dust from the unit. Sounds good ... but it does not play well with dust collection. In fact, if I connect it to my Oneida V3000, it will overpower the suction from the V3000's 3hp motor and fill the HEPA filter in relatively short order. That's not good.
I experimented with connecting the DW735 to the ductwork of the V3000, but not turning on that system. That actually worked a little better than when I turned the V3000 on, but it still didn't work well. The DW735 actually blew dust into every pipe in the dust collection system; it ejected dust through any open gate (I did typically have my table saw gate open, and it filled the cabinet of the saw!). Using the existing ductwork didn't work well ... I needed an independent system.
Research led me to believe that I really needed to collect the dust more than I needed to suction it out of the unit with its powerful onboard motor.
Since I like my current Oneida cyclone, I ordered their Dust Deputy 10 gal. Deluxe Cyclone Separator Kit through Amazon. I paired that mini-cyclone not with a shop vac, but with a 3 micron bag from Powertec.
Reviews of the Powertec bag had some buyers attaching the bag directly to the DW735, but that meant frequent emptying of the bag through it's small opening. Using the cyclone separator in tandem seemed like a good idea.
After 1 day's use ... it's a good idea. Definitely filled up the 10 gallon can several times, and the Powertec bag kept most of the dust from leaving the system. It does seem, however, that the bag adds some back pressure to the system; there was a noticeable (though small) increase in the shavings left on the workbench that ejected from the front of the DW735. In addition, when I did a blade change, I found that there were more shavings than normal collected in the interior of the unit.
In total, however, collecting the dust in the 10 gallon can was much better than the previous system using the existing duct work and overpowering my V3000.
The unit came with a slip on hose for connecting the cyclone to a tool; that hose slipped off easily. I used some tape to hold it in place for this inaugural use; now I need to get better connectors for both ends of the hose to make it as portable and easy to use as possible.
The bag did not inflate as it might appear in the photos; I leaned the partially inflated bag up against the adjacent router table.
I don't think this is a perfect system (not a HEPA rated bag at 3 microns & the DW leaving more shavings on the cutting edge is worrisome), but it's a material improvement.
While he was doing his work, I was confronting a relevant problem in my shop: how to best collect the dust generated by my DeWalt 735 planer. That benchtop planer is excellent (I'm on my 2nd unit after wearing out the 1st), and has an onboard blower that ejects the dust from the unit. Sounds good ... but it does not play well with dust collection. In fact, if I connect it to my Oneida V3000, it will overpower the suction from the V3000's 3hp motor and fill the HEPA filter in relatively short order. That's not good.
I experimented with connecting the DW735 to the ductwork of the V3000, but not turning on that system. That actually worked a little better than when I turned the V3000 on, but it still didn't work well. The DW735 actually blew dust into every pipe in the dust collection system; it ejected dust through any open gate (I did typically have my table saw gate open, and it filled the cabinet of the saw!). Using the existing ductwork didn't work well ... I needed an independent system.
Research led me to believe that I really needed to collect the dust more than I needed to suction it out of the unit with its powerful onboard motor.
Since I like my current Oneida cyclone, I ordered their Dust Deputy 10 gal. Deluxe Cyclone Separator Kit through Amazon. I paired that mini-cyclone not with a shop vac, but with a 3 micron bag from Powertec.
Reviews of the Powertec bag had some buyers attaching the bag directly to the DW735, but that meant frequent emptying of the bag through it's small opening. Using the cyclone separator in tandem seemed like a good idea.
After 1 day's use ... it's a good idea. Definitely filled up the 10 gallon can several times, and the Powertec bag kept most of the dust from leaving the system. It does seem, however, that the bag adds some back pressure to the system; there was a noticeable (though small) increase in the shavings left on the workbench that ejected from the front of the DW735. In addition, when I did a blade change, I found that there were more shavings than normal collected in the interior of the unit.
In total, however, collecting the dust in the 10 gallon can was much better than the previous system using the existing duct work and overpowering my V3000.
The unit came with a slip on hose for connecting the cyclone to a tool; that hose slipped off easily. I used some tape to hold it in place for this inaugural use; now I need to get better connectors for both ends of the hose to make it as portable and easy to use as possible.
The bag did not inflate as it might appear in the photos; I leaned the partially inflated bag up against the adjacent router table.
I don't think this is a perfect system (not a HEPA rated bag at 3 microns & the DW leaving more shavings on the cutting edge is worrisome), but it's a material improvement.
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I recall watching a video of a DC build specifically for the 735 that was extremely simple. It was just box (or drum would do) with a framed screen on top tha relied on the DeWalt blower to move the fluffy shavings. Box has an unobstructed input direct from the machine. The exhause on the box was covered with a simple screen and allowed the air to exhaust freely but keep the sawdust contained. Here are some variations on the idea.
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