On Jan 30, 2025, at 11:05?AM, Bill Belanger via groups.io <bllblngr@...> wrote:

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I printed this a year ago for a fellow who says it has worked out well for him. It’s not my design and I can no longer find the STL file and I don’t remember where I found it. My plan was to redesign it to make it stronger because it’s a bit flimsy, but I believe I could just print it with more infill (thicker) to solve that. I’m on vacation now but I’ll be back in 2 weeks and I can keep working on this if there is interest. We were going to work on improving the attachment.

Bill Belanger?

On Jan 29, 2025, at 21:55, mike chin via groups.io <mike.spcr@...> wrote:

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[Edited Message Follows]

CAUTION!!?

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I was in the saw this morning, replacing the old now-stiff & brittle 4" internal hose between the 3D printer coupler & the exhaust port at the bottom front. When the saw is tilted, beyond about 40 degrees, the hose gets trapped between the motor and the side wall, at which point the hose resists bending, and it is quite hard to set the tilt all the way to 45 degrees. A rib on the side wall protrudes about an inch, which also adds to the impedance.?

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See the illustrative pics.

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Blade at standard tilt, from above

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Blade at standard tilt, from below front.

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Blade at >40 deg, from below. Hose gets jammed against side wall & rib.?

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This problem must occur with the standard hose setup, too, because there's really no room for the hose between the side wall and the motor when the blade is at extreme tilt. Which is why the original hose kept falling off in the first place.

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Anyway, it is unfortunate, but perhaps not a deal breaker for everyone: I apparently have not used the saw tilt beyond 40 degrees for a year. I usually use my 10" miter saw for 45 deg angled cuts.?

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One possible solution is to use as flexible a hose as you can. The copper wire hose was the only 4" hose in stock at the nearest tool store yesterday; an all-plastic more flexible one would have been a better choice.?

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Another solution is to modify the coupler design so that the round exhaust points directly downward from the rectangular interface and perhaps a bit toward the inside of the saw casing -- ie, towards the motor. The coupler needs to be kept as small as possible to keep it from fowling the max tilt position.?

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Further investigation shows when the saw is tilted fully, there's at most one inch distance between the bottom of the trapezoidal metal dust collection device and the side wall in the saw. The saw was never designed properly to accommodate the dust collection hose when tilted to 45 degrees. No wonder my original duct hose kept falling off!?

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So if you choose to use the 3D printed coupler here, DO NOT TILT THE SAW >40 degrees. You will risk breaking the coupler and damaging the hose. I think this probably holds true for standard dust collection hose mounting too unless a very flexible hose is used.?