Woodworker's Journal 2007-Winter, страница 37




Woodworker

MATERIAL LIST - Downdraft Sanding Box

T x W x L

T x W x L

1 Ends (2)

3/4" x 31/2" x 23"

5 Bottom Halves (2)

1/4" x 11" x 3414"

2 Sides (2)

3/4" x 31/2" x 36"

6 Bottom Tape (1)

Duct Tape

3 Long Cleats (2)

3/4" x 11/2" x 3412"

7 Top (1)

1/4" x 23" x 351/4"

4 Short Cleats (4)

3/4" x 11/2" x 20/2"

8 Glue Blocks (4)

3/4" x 1" x 1%" .

Start construction by cutting the ends, sides and cleats (pieces 1 through 4) to size, then secure the corners with glued and nailed butt joints. Cut the bottoms (pieces 5) next, and install them in two halves to form a slight V-shape, as shown in the Exploded View above.

The V-shape creates a valley that catches dust and funnels it more efficiently toward the vacuum. To begin, glue and nail (or screw) all four cleats in place, at the locations shown on the Corner Detail drawing above. Cut the bottom to size and temporarily install the two halves.

Clamp a few scraps to the sides, just to hold the bottom in place for a minute. Then turn the assembly upside down and apply duct tape (piece 6) along the joint. Turn it back upright and secure the bottom to the cleats with small

nails or brads, squaring the box as you fasten the joints.

The top (piece 7) is nothing more than a piece of 1/4" pegboard. We used a brand with a finished face to help prevent scratching. You can cut it to rest on the top and secure it with duct tape or trim it to fit just inside the box and let it rest on the bottom. Either method allows for easy replacement when it gets a worn. If the top flexes too much, add a couple of band-sawn triangular cleats to the carcass ends.

Hooking It Up

Attaching a vacuum or dust collector hose is generally just a matter of drilling the right size hole for the hose end. Or, you can buy a flange that screws to the box to connect your dust collector or vacuum hose. Bring your hose to a home center and spend a little time

We use a shop vacuum with a special switch designed to be used with dust-creating power tools. When you plug your sander into the vacuum, each time you start the tool the vacuum turns on as well. When you turn your tool off, the vacuum continues for a short time to catch the last bit of dust.

in the plumbing aisle to find the right connector; there's bound to be one that fits. Virtually any size dust collector will work with this project, but it goes without saying that bigger is better — just be sure to wear ear plugs. ^

Winter 2007

37



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