Easy Chip and Dust Collection for DeWalt 735 (DW735) Planer
Updated: Nov 9
How much fine sawdust is your dust collection setup allowing you to breathe in? A HEPA grade filter prevents dust particles down to .3 microns from entering the air around you. But the DW735 isn't meant to hook up to a dust collection system, so how do you add a filter?
Like figuring out how to price your woodworking projects, keeping the air clean in your woodworking shop is a challenge. Breathing clean air an absolute necessity for your health. If you are a DIY hobbyist, chances are you don't have an expensive, dedicated dust collection system. Most of us get started with by connecting a shop vacuum to the tool with a hose. While this is enough to get by starting out, a few issues pop up rather quickly:
Clogged filters - chokes your vacuum, reduces suction power and strains the motor
Vacuum fills up fast - constantly needing to empty dust and chips from the vacuum
Harmful particulate - microscopic particles emitted into your shop and into your lungs
An easy, DIY dust collection for your DW735 planer can alleviate these problems. We'll talk about an easy setup can be completely assembled in less than 20 minutes.
This set up is specific to the DeWalt 735 thickness planer due to its built-in chip ejection, but with a small modification, it can work for other wood cutting tools in your shop.
Affiliate links to the products used are included throughout to assist you in building your own DIY dust collection setup. As an Amazon Associate I earn from qualifying purchases. Making purchases through these links doesn't cost you anything additional!
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The DeWalt 735 Planer
DeWalt 735 Planer (Amazon)
This planer is one of the most common small-shop thickness planers. One of its main benefits is the internal chip blower. This evacuates wood chips without the need of a vacuum or expensive dust collector. All you need is a simple collection system that is easy to set up, takes up minimal space and keeps your shop air safe to breath.
Dull blades? Get your replacements here. (Amazon)
Upgraded helical blades (Amazon) produce a smoother finish and drastically reduce the noise.
Don't let the noise from DW735 run you out of your shop or upset your neighbors. Find out how to dampen and absorb shop noise.
What is the difference between DeWalt 735 and 734?
The DW735 (and DW735x) are the current benchtop models offered by DeWalt. The DW734 is the previous model offered. The main difference is the built-in chip extraction present on the DW735 but missing from the DW734. Learn more.
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A quality dust collection system requires 4 components: dust separation, collection, filtration and the hose to bring it all together.
For quick access to the chip collection supplies you will need:
Collection bin (jump to section)
Cyclone separator (jump to section)
Filter (jump to section)
Hose (jump to section)
For little more than 100 bucks, you can get everything you need.
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Chip Collection for DeWalt Planer
Many use trashcans, but have difficulty with keeping the lid from getting blown off under the pressure. You want to maintain an airtight seal to keep harmful dust particles contained while, at the same time, allowing the system to breath. Consider how often you create dust and your shop space to determine how big of a container to use.
There are two good small size options and a more expensive extra large option:
14 gallon plastic drum (Amazon)
30-gallon plastic drum (Amazon) recommended
Extra Large 55-gallon drum (Amazon)
I use the 14-gallon drum, but I regret not upgraded to the 30-gallon. The 14 gallon fills up pretty quick. If I'm consistently planing wood, I', emptying it every 20 minutes. The prices keep fluctuating on these, but the 30-gallon is hovering at about $20 more than the 14-gallon. The 50-gallon is quite expensive, making the 30-gallon the happy medium.
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Cyclone Dust Collector Separator
Cyclone separators are an absolute necessity in your dust collection setup.
The cyclone inlet sends woodchips in a spiral path downward along the inside walls of the cyclone into a collection bin below. The outlet port protrudes down into the cyclone allowing air to vent up through the center of the cyclone and out the top.
This will prevent your air filter from getting clogged. Since the wood chippings fall into the bin, the air that vents out is mostly clean. The debris smaller than what you can see escape to the filter.
I've been using this setup for well over a year and have yet needed to replace the filter.
Read more: How Cyclone Separators Work.
I recommend the solo Dust Deputy (Amazon), but Oneida offers a couple additional solutions for those looking for a smaller all-in-one package.
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Dust Collector Filter: High Efficiency vs HEPA
This is where the setup deviates if you are not hooking this up to a tool with its own chip ejection built in. For those tools, you simply hook up a vacuum hose to the top of your cyclone, but you still need a quality filter installed inside the vacuum to ensure you aren't breathing in harmful particulate ejected from the exhaust port. The bigger the filter, the more airflow and less strain on your system. Full-size shop vacuum filters work great, but at minimum, you want a High Efficiency filter.
High Efficiency Dust Filter: Good
RIDGID 3-layer (Amazon) filter will protect you against most shop debris such as wood, drywall and general dust down to 1 micron in size. This is the minimum level protection you want in a shop filter.
HEPA Dust Filter: Best
HEPA takes it one step further to filter dust as small as 0.3 microns. This will block mold spores, dust mites and other allergens. Not a name brand, but is what I use. They can find them at Amazon often for less than the High Efficiency by RIDGID.
How to Connect a Filter to a Cyclone Separator
Connecting your Dust Deputy cyclone separator to a full-size filter is easy with two reducing couplings:
4"x 3" PVC Sewer and Drain Coupling (Amazon)
3"x 2" Rubber Reducing Coupling (Amazon)
Be sure it is not a regular Drain/Waste/Vent (DWV) coupling - these have a thicker diameter and will not fit.
The rubber reducing coupling secures to the outlet port of the dust deputy with the PVC reducing coupling on the top side. The filter friction fits to the top of the PVC coupling.
Note: Some filters fit more snug than others. A thick double sided tape works well to keep the filter airtight.
Some filters have a hole in the center top. Plug it by taping the underside and filling the hole with silicone or other adhesive. I did this to mine and don't have any air leaks a year later.
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DeWalt Planer DW735 Dust Port
The dust port of the DW735 planer can accommodate two hose sizes. It measures 3-15/16" to fit a 4"dust hose. The true port size is 2-7/16" which will stretch fit a 2-1/2" hose.
Anti-Static Dust Collection Hose
The DW735 dust port will accommodate a 4" hose, but ejects chips through a 2-7/16" port. I use a 4" hose to reduce the possibility of the hose getting clogged up, but requires installing an adapter (below) to reduce down to the inlet port of the cyclone.
My biggest regret was opting for the cheaper dust collection hose instead of an anti-static version. The DW735 creates a good amount of static that never fails in zapping my hand if it touches the hose while it is running.
Though I recommend the 4" hose, 2-1/2" hose will work for most and has the added benefit of eliminating the need for the adapter to the cyclone.
4" x 10' Anti-static hose (Amazon) - requires adapter below.
2-1/2" Anti-static dust hose (Amazon) -no adapter needed
4" Hose clamps (Amazon)
Adapter - Required if using 4" dust hose
4" x 2-1/4" Adapter (Amazon) to connect your 4" hose to to the dust cyclone inlet port.
The outside diameter of the large end will fit to the hose with hose clamps to tighten down. The 2-1/4" end will snug fit to the cyclone, but you can add glue or tape to seal it extra tight.
I was worried the pressure would blow the filter off, and after 6 months or so, this did happen. I wasn't paying attention to how full my collection bin got and the pressure eventually blew the filter off. I realized now, double sided tape is the way to go - and also checking my collection bin more often!
The tape holds the filter tight to the coupling and prevents air leaks much better.
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From start to finish, you need:
Hose - Choose 2-1/2" hose with clamps or 4" hose with adapter and clamps
2-1/2" Anti-static (Amazon) - Smaller diameter, adapter to cyclone not needed
4" Anti-static (Amazon) - Low clog chance, but requires an adapter to cyclone
4"x 2-1/4" Adapter (Amazon)
4" Hose clamps (Amazon)
Cyclone Separator - Select which cyclone separator you prefer
Dust Deputy (Amazon)
Dust Deputy (full kit) (Amazon)- includes collection bucket and 2.5" hose
Collection - 30-gallon is recommended, but 14-gallon works
14-gallon drum (Amazon)
30-gallon drum (Amazon)
Fittings - both fittings are needed to attach the filter to cyclone
4"x 3" PVC Coupling (Amazon)
3"x 2" Rubber Coupling (Fernco) (Amazon)
Full-size Filter - HEPA or High Efficiency filter
HEPA (Amazon)
High Efficiency (Amazon)
Double-sided Tape (Amazon)
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Cyclone Dust Collection Kit for DeWalt Planer
To simplify this further, I built these kits that contain everything you need? Select the kit with the corresponding hose size you'd like: 2-1/4" or 4"
Click the text bar at bottom of each kit to view full kit. The kit links navigate you to an external site that packages everything you need to order this setup from Amazon. You do not pay extra for using these or any links on this page.
1. 30-Gallon / 4" Hose Kit (Amazon) - includes all you need to set up with the 30-gallon drum with 4 inch hose.
2. 30-Gallon / 2-1/2" Hose Kit (Amazon) - includes all you need to set up the 30-gallon drum with 2-1/2" hose.
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DeWalt DW735 Dust Collection Bag
Don't need HEPA grade filtration or want a cheap alternative?
There are other options to control dust emitted from the DW735 that come with their own set of pros and cons. One of the most common and cost effective solutions is a dust collection bag. While their convenience and cost make this option attractive, those concerned with HEPA-grade filtration won't find these to be much help as they typically filter down to only 5 microns. If you just need a simple collection bag and aren't concerned about HEPA-grade filtration, there are several options that will work:
Dust Right Dust Collection Bag by Rockler (Amazon)
This dust collection bag was designed as a replacement for wall-mount dust collector filters, but is also advertised as a great collection bag for thickness planers like the DW735.
5 micron filtration
Approximately 14" wide x 24" long
$$$ - Expensive
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POWERTEC Dust Filter Bag (Amazon)
Another replacement for a wall-mount dust collector, but with better filtration. For the money, this is the best option.
1 micron filtration
14" wide x 24" long
$S - Affordable
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Big Horn Dust Filter Bag (Amazon)
The most affordable, but worst filtration. This can be useful if you are running your DeWalt 735 outside.
30 micron filtration
13-1/2" wide x 24" long
$ - Cheap
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Now you're all set and ready to mill your wood with peace of mind knowing you are protecting your lungs without much hassle! We'd love to hear if you use this setup or how you've done dust collection differently in the comments below.
You can also get great results with complete kits that are just now hitting the market if you don't want to DIY.
Find that perfect gift or get ideas to build your own holiday wish list with the 2023 Woodworker Holiday Gift Guide.
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