To protect and enhance your table saw, you can create two essential covers: a custom dust collection hood and a padded storage cover. The dust hood improves safety and cleanliness during operation, while the storage cover protects the saw when not in use. This guide will walk you through the materials, dimensions, and design features needed for both projects, helping you create effective and tailored solutions for your table saw.
What Materials Are Needed for a Table Saw Dust Hood?
To construct an effective dust collection hood for your table saw, you’ll need the following materials:
- 6MM MDF or ¾” plywood for the main structure
- ¼” thick acrylic or PVC clear sheeting for the face
- 4″ (100 mm) round duct, 2 ft (600 mm) long
- Two 4″ (100 mm) articulating duct elbows
- Self-tapping sheet metal screws
- Foil duct tape
- 4″ to 2.5″ dust adapter
- EVA Foam Sheet for sealing gaps
- Duct tape for sealing seams and connections
How to Design the Dust Collection Hood?
When designing your dust collection hood, consider these key features:
- Attachment to the Saw:
- Trim the hood to fit the opening below the saw
- Use sheet metal screws or suitable fasteners for attachment
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Ensure adjustability for different cutting angles
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Ductwork and Elbows:
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Attach an articulating elbow to direct dust downwards at a 45-degree angle
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Sealing Openings:
- Cut covers for back and side openings using MDF or plywood
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Use screws or magnets for easy attachment and removal
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Adjustable Shroud:
- Include an adjustable window for various cuts and blade changes
What Materials Are Required for a Padded Storage Cover?
For a durable and protective storage cover, gather these materials:
- Heavy-duty polyester or vinyl fabric (0.5 mm to 1 mm thick)
- Foam sheets or thick fleece (5 mm to 10 mm thick) for padding
- Waterproof fabric with PU coating or similar treatment
- Elastic strips for edges
- Zippers or Velcro strips
- Handles or straps for easy handling
How to Determine the Dimensions of the Storage Cover?
To ensure a proper fit for your storage cover:
- Measure your table saw’s length, width, and height
- Add an extra 2-3 inches to each measurement for overlap
- Typical dimensions might be around 60″ x 40″ x 30″, but adjust according to your saw’s size
What Design Features Should the Storage Cover Include?
Incorporate these features for a functional storage cover:
- Elastic Edges:
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Sew elastic strips into the hem for a snug fit
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Closures:
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Add zippers or Velcro strips for easy installation and removal
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Handles:
- Attach sturdy handles or straps for convenient handling
How Much Will These Projects Cost?
Here’s a breakdown of estimated costs for both projects:
| Item | Estimated Cost |
|---|---|
| MDF or Plywood | $10-$20 |
| Acrylic or PVC | $20-$30 |
| Ductwork and Connections | $20-$30 |
| Waterproof Fabric | $15-$30 |
| Padding Material | $10-$20 |
| Fasteners and Accessories | $5-$10 |
| Total Estimate | $80-$140 |
What Techniques Are Used in Construction?
To build your covers effectively:
- Use a band saw or jigsaw for cutting MDF or plywood
- Cut acrylic or PVC with a CNC router or jigsaw and drill
- Sew the fabric cover using a heavy-duty sewing machine
- Apply additional waterproof coating if needed
By following these guidelines, you can create custom covers that will protect your table saw, improve dust collection, and extend the life of your valuable tool.
References:
1. Adding Dust Collection to a Contractor’s Table Saw
2. Designing a DIY dust hood solution for my table saw
3. Dust-Free Blade Cover