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20th July 2020, 06:19 PM #1Senior Member
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- May 2009
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- Peoples Republic of Bryn
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- 393
Made a Overhead Dust extractor boom for the Hammer K3
Well, i've been meaning to sort out the dust extraction for the saw guard, so i decided i'd whip one up, as i had a spare 80mm port on my Felder dusty that i could use along with the 120mm port.
I decided to mount it to the K3, with all the load on the concrete. its only bolted with rubber washers to keep it attached to the machine.
The frame is balanced via a 3 way leg, with the two adjustable feet next to the machine, this allowed me to adjust the height to take the pressure of the table and adjust the level.
I ended up using 80mm DWV, as i had 80mm flexible pipe already with a 80mm to 50mm reduction and a small piece of 50mm flex hose, i used 80mm pipe mounts with 10mm weld nuts to offset the pipe from the frame.
I also used 75mm x 25mm x 2.5mm RHS for the frame and some 50 x 50 x 3mm angle iron for the leg adjustment and a few weld nuts for the adjustable feet, i also put in a few rivnuts to hold some cheap hangers for the hose and power lead.
I could have got away with 50mm x 25mm RHS, but i had some 75mm x 25mm, so i used that and used the Mig to weld it up, a coat of red primer and two coats of Hammertone black and it came up good enough for me.
All the overhead measurements to centre the hanging hose worked out and there isn't any pressure on the safeguard or riving knife.
I haven't glued the DWV pipe joints yet, i'm deciding on if i'm going to paint the DVW, i'm tempted to paint it in the same red as the hammer machines if i find a paint code for it.
This is how i did it, there are most likely better ways, but i just thought i'd put it out there if someone was thinking of making their own.
Cheers,
Bryn
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20th July 2020 06:19 PM # ADSGoogle Adsense Advertisement
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20th July 2020, 07:14 PM #2SENIOR MEMBER
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- Oct 2005
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- North Balwyn Victoria
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Nice job!! Terrazzo floor as well?
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20th July 2020, 07:26 PM #3
Most likely epoxy floor. Looks good.. so to the o/head extraction.
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20th July 2020, 08:02 PM #4.
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- Perth
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Nice arm, but I worry about how much fine dust will get through such a restricted hood intake.
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20th July 2020, 08:50 PM #5Senior Member
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- May 2009
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- Peoples Republic of Bryn
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- 393
Yeah it is an epoxy floor, its seen better days, but is holding up well, apart from where the cracks in the slab and a few chips.
I knew BobL would chime in, he is never happy and would find flaws in a NASA built spaceship
But he is right, it would be better with a bigger hood intake, but i'm keeping with the factory hood for now, unless anyone wants to 3D print a custom hood for the K3 with an 80mm intake.
But at the end of the day, any dust extraction is better than none.
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21st July 2020, 05:22 PM #6GOLD MEMBER
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- Jun 2005
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- Helensburgh
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- 7,696
The overhead for a K3 is a problem and more of a problem when you haven't got a a low ceiling to hang the extraction pipe from and the mechanical restrictions of the saw limit the width of the hood unless all the added width is all to one side. Mine works tolerably well though and I haven't worried about making a new one apart from the wish to get it off the riving knife.
CHRIS
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22nd July 2020, 06:44 AM #7Senior Member
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- May 2009
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- Peoples Republic of Bryn
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That is why i went with a floor mounted option, my ceiling is 6 mtrs high and i didn't want to span a swing arm 2.7mtr from the wall.
It would be possible to for someone to print an improved verison of the saw guard/hood, with a increased suction area and larger inlet.
I might have a crack at making a new hood in clear perspex and plastic welding it together with a larger inlet, but for now i have too many other projects on the go
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22nd July 2020, 10:00 AM #8.
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- Feb 2006
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- Perth
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- 27,792
I've spend many hours measuring air flows and dust levels around various saw hoods and come up with 3 factors to consider in maximising air flow and hence fine dust removal.
1) The back of the guard should be as open as possible ie completely open. This is one reason why Gilders sounds like works so well. Most guards are semi sealed down boxes - if little or no air can get in resulting in not much fine dust getting out.
2) The best location for max dust extraction that leaves some visibility is directly above where the blade enters the saw plate. Other locations fight the air currents generated by the blade which are substantial. Unfortunately this does still somewhat restrict the view so some comprises may need to be made.
3) When the above are implemented a 4" hose is usually enough. I have to turn of my DC when docking small pieces as they endup being sucked away.
And, as CP says, to make narrow cuts and still cover the blade the hood has to have most of its structure on one side or have some sort of lateral adjustment.
It's taken me 4 goes to get these all into a workable system. I'm lucky that I have the underside of a roof truss 2.4m above the floor immediately above my saw and am able to suspend it from there. It's also able to pivot the guard from side to side to generate enough lateral adjustment.
The WIP for mine is here.
Ducting update.
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22nd July 2020, 01:30 PM #9
Why not continue the horizontal beam back towards the wall and run your main hose over that way instead of across the floor??? Nothing I hate more than dust-hose across the deck
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22nd July 2020, 04:03 PM #10Senior Member
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- May 2009
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- Peoples Republic of Bryn
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- 393
Because it's a 30 second job to disconnect and roll up the the 80mm overhead line and 120mm lower machine hose with the fender quick connects.
When using the K3, i never need to go around the back or that side of the machine when in operation.
If i didn't need to move the K3, A3-31 and N4400, id have an overhead extraction system.
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22nd July 2020, 04:24 PM #11Senior Member
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- May 2009
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- Peoples Republic of Bryn
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Good info Bob,
It does surprise me how poor the dust extraction is in within this industry, when doing my cabinetmaking apprenticeship in the 90's, PPE and Air quality control wasn't taken seriously, its a little bit better, it depends on who you work for.
It wasn't until i worked on a few Union site jobs that required a full sealed cutting area for MDF that i appreciated decent dust control, it was part of the reason i switched over to Festo/Festool as i could comply better on site with the integrated dust vacuums.
The K3 main dust extraction port on this machine is 120mm, yet the internal hose is 100mm and a poorly designed collector around the blade.
One big thing i've noticed that has made an improvement in my workshop is the Poly drum filter with poly sleeve (M class dust rating (Cat 3) on my Felder AF16
Fine dust is one of those things that is hard to control, but would be a lot better if machines were designed better.
For a while i had a guy in the next shed that didn't use a dust extractor, he always seemed to have a 1 inch layer of wood shavings and dust all over the floor from the cabinetsaw and jointer/thicknessor, i don't know how he put up with it.
It freaked me out one day, when i saw him welding in the shed with that crap all over the floor.
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22nd July 2020, 07:37 PM #12.
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- Feb 2006
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- Perth
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Yeah the problem with dust is that it usually takes years to have an affect and like smoking it might be not be direct. It's now known that any dust contributes to cardio vascular problems and makes most other diseases worse.
It takes a special kind of discipline to avoid even a 3 second job - "Argh - I won't bother setting up/turning on the DC. . . . . this time". That's why I don't recommend mobile machines. In my various visiting to a bunch of DIY and mens sheds its the mobile machined sheds that are usually the dustiest. Auto blast gates are the go but they are expensive for a DIY on a budget. The other thing about mobile machines is the (excess) use of flexy which is a sure fire way to restrict flow. OK - sometimes there is not many other options. I can understand that
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22nd July 2020, 08:45 PM #13Senior Member
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- May 2009
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- Peoples Republic of Bryn
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I must have a different though process bob than others, if my dusty isn't connected and going, i don't use the machine period, you only use them together.
Having said that, I've lost close friends from Mesothelioma and also my old man to lung cancer, so maybe i look at minimising dust a little more seriously.
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