DownDraft Box - Router Forums
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post #1 of 30 (permalink) Old 09-03-2018, 10:51 PM Thread Starter
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Default DownDraft Box

Here is a downdraft box I just completed today for sanding with my ROS. I used the Rockler plan pdf. that I downloaded off their site .

http://go.rockler.com/tech/25077-Down-Draft-Ezplan2.pdf

I had a part of a sheet of prefinished 1/2"birch plywood I had bought and used for drawer sides. The box is pretty simple to build. I made my own perforated top pieces. I had built one years ago off the same plan, but they had small 1/2" holes and it cut the air flow so much ,I decided to make the holes 1' dia. spaced 1/4" apart.

I tried several drill bits to drill the holes and settled on the spade bit with the scoring ears on it.
I tried a Forstner type bit, and it cut OK from both sides, but it was slower, plugged up,was harder to exactly follow the pilot hole as the pilot point was so short.
The 2 auger type bits were the best cutters, but the threaded pilots would lift the material off table table fast.
The spade bit has a long tapered pilot that centers from both sides easily and the spurs do a good job of scoring the outside cut. I never would have guessed it ,but it worked best for drilling from both sides.

It took the longest to drill and finish all 278 holes.

The pictures tell the story.

Herb
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post #2 of 30 (permalink) Old 09-04-2018, 02:14 AM
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World's largest 'Whack-a-Mole' !
Again, Herb, beautifully crafted...have you put it to the test yet?
Just out of curiosity, why does it have to be so deep, top to bottom?
JFPNCM and OutoftheWoodwork like this.
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post #3 of 30 (permalink) Old 09-04-2018, 02:38 AM
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Quote:
Originally Posted by DaninVan View Post
World's largest 'Whack-a-Mole' !
Again, Herb, beautifully crafted...have you put it to the test yet?
Just out of curiosity, why does it have to be so deep, top to bottom?
that's controlled by the thickness of the bed and the dia of the pickup..
JFPNCM, DesertRatTom and jj777746 like this.

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!!!
"SNORK Mountain Congressional Library and Taxidermy”
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post #4 of 30 (permalink) Old 09-04-2018, 02:39 AM
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Herb...
you gonna put hardware cloth on the bottom side of the deck for small part loss control???
DesertRatTom, TenGees and jj777746 like this.

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!!!
"SNORK Mountain Congressional Library and Taxidermy”
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post #5 of 30 (permalink) Old 09-04-2018, 06:49 AM
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Herb, that is a very nice build. You might have too many holes or the holes might be too big. My box is I think too big and the holes are too big. I have it hooked up to my big dust collector and it doesn't seem to be pulling enough air.


Don in Murfreesboro,Tn.

Measure once cut twice and it's still to short.
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post #6 of 30 (permalink) Old 09-04-2018, 07:43 AM
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Nice, Herb. I went with my own design a year ago, still works great and with the DC hooked up it really pulls hard and will hold a piece in place if I block off the rest of the holes (easy to do).


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post #7 of 30 (permalink) Old 09-04-2018, 07:52 AM
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Hmmmmmm!!!

That sure looks like HF gray one handed clamps being used!!

Herb I thought that they went by the wayside a while ago.
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post #8 of 30 (permalink) Old 09-04-2018, 12:24 PM Thread Starter
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Originally Posted by smitty10101 View Post
Hmmmmmm!!!

That sure looks like HF gray one handed clamps being used!!

Herb I thought that they went by the wayside a while ago.
I think you are right. The mini ones seem to hold fine, it is the large ones like the Irwins that don't hold good, and pinch your hands, good eye.
Herb
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post #9 of 30 (permalink) Old 09-04-2018, 12:35 PM Thread Starter
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Quote:
Originally Posted by hawkeye10 View Post
Herb, that is a very nice build. You might have too many holes or the holes might be too big. My box is I think too big and the holes are too big. I have it hooked up to my big dust collector and it doesn't seem to be pulling enough air.

Haven't got it hooked up yet, so don't know how well it works. Might have to seal off some holes. I will pick up some fittings and flex to do a hook up this week.

The last one I made with 1\2" holes didn't do the job.

@stick 486
no hardware cloth

Thanks for all the comments, I will have some things to think about.

Herb
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post #10 of 30 (permalink) Old 09-04-2018, 03:47 PM
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Herb's project is a beauty. I wonder if you could make the box, then use one of the plastic or metal grids that go on flourescent light fixtures. Then have a couple of thin, rectangular masks with rectangular openings to lay over it, leaving openings just a little larger than the item being sanded? You could add a small chamber below the unit to slide in and store the masks out of harm's way. Just thinking.

I really like Stick's idea of, say a 1/4 or 1/3rd inch wire screen below the grid to strengthen it and catch dropped small parts. I'd also use very light weight materials wherever possible so I didn't get a hernia every time I hauled it out for use.

I think I'd put some very smooth material on the slanted boards to keep sawdust from hanging up on tiny rough spots.

The more I do, the less I accomplish.

Last edited by DesertRatTom; 09-04-2018 at 03:49 PM.
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