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Author Topic: Cooling Air Diverter for DeWalt router  (Read 9509 times)
atwooddon
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« on: February 23, 2012, 01:29:46 am »

I got tired of the downdraft from my DeWalt DWP611 spreading the dust before it could be picked up by the vacuum.  The DWP611 is variable speed and has 2 LEDs in the base on either side of the spindle to light up the cut area which is very nice.  I have used this router for about 40 hours now and it still runs like new.  There didn't appear to be any easy way to mount the deflector to the bottom of the router until I notice there were 2 screws that held the shaft lock button assembly in place.  So, I designed an air deflector that would use those 2 screws as the attach point.  All you need to do is find 2 matching screws that about 1/4" longer.  

It seems to work great, the chips and dust don't get blown around much at all making the vacuum pickup much more effective.  Below are 2 pictures of the deflector right after cutting.  The only thing you have to do is counter sink the 2 attach holes on the bottom with holes big enough to clear the screw heads.  I will post of a picture of it mounted after the paint dries.

Don



* Deflector1.jpg (259.1 KB, 818x754 - viewed 850 times.)

* Deflector2.jpg (146.17 KB, 633x598 - viewed 598 times.)
« Last Edit: February 23, 2012, 01:43:11 am by atwooddon » Logged
atwooddon
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« Reply #1 on: February 23, 2012, 01:46:49 am »

Here is the deflector mounted on the bottom of the router.  You can see how the LEDs light up the work surface below the deflector.

I also attached the .cb file for the part if you would like to make one.  I used an 1/8" endmill and 3/4" MDF. 

Don



* Deflector3.jpg (657.55 KB, 1159x1043 - viewed 1409 times.)
* DWP611-Diverter.cb (19.37 KB - downloaded 445 times.)
* DWP611-Diverter.nc (123.39 KB - downloaded 415 times.)
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Bob La Londe
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« Reply #2 on: February 23, 2012, 02:12:12 am »

I've been using Bosch Colt and now Porter Cable routers for a while for high speed milling aluminum.  They work fairly well, but I think the air flow throws coolant around a lot and probably wastes a lot of coolant.  I've thought about doing something like what you showed there, but in aluminum or steel for obvious reason. 

Nice job. 

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atwooddon
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« Reply #3 on: February 23, 2012, 04:04:56 am »

Bob, I painted it bright silver, can I pretend it is aluminum?  ;-)

Don
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« Reply #4 on: April 26, 2012, 20:32:22 pm »

That's very nice and compact.  I designed a diverter for my Porter Cable 892 for the same reason, made easily, inexpensively, water proof and has suction attachment for vac hose.  Mainly used with wood and acrylic cutting,  and some light aluminum drilling.  Perfect for routers with round housings.

My original post is here: http://www.cambam.co.uk/forum/index.php?topic=1725.0


« Last Edit: April 26, 2012, 20:33:53 pm by airnocker » Logged

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