Updated: Jan 19
ow much fine sawdust is your dust collection setup allowing to enter your lungs? A HEPA grade filter prevents dust particles down to .3 microns from entering the air.
Keeping the air clean in your woodworking shop is a challenge but 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. This 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!
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.
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 all the materials you need.
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:
I use the 14-gallon drum, but wish I would have upgraded to the 30-gallon. The prices keep fluctuating on these, but the 30-gallon is hovering at about $20 more than the 14-gallon, but worth it for the additional capacity and slight increase to the footprint.
TIMber Woodwork Easy Dust Collection Kit
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 prevents your air filter from getting clogged. Since the wood chippings fall into the bin, the air that vents out is mostly clean. Mostly debris smaller than what you can see escape to the filter. Read more: How Cyclone Separators Work.
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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.
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:
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.
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.
2-1/2" hose will work for most and eliminates the need for the adapter.
4" x 10' Anti-static hose (Amazon) - requires adapter below.
2-1/2" Anti-static dust hose (Amazon)
4" Hose clamps (Amazon)
Adapter - only needed if using 4" hose
4" x 2-1/4" Adapter (Amazon) to connect your filter to the dust cyclone output port.
The outside diameter of the large end will friction fit nicely to the full-sized filters. This isn't necessary if you are connecting the cyclone output port to a vacuum.
I was worried the pressure would blow the filter off, but have had no issues so far. Should it happen, a couple rounds of tape on the 4" side of the coupling will improve the friction fit.
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 required
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
Dustopper from Home Depot
Collection - 30-gallon is recommended, but 14-gallon works
Fittings - both fittings are needed to attach the filter to cyclone
Full-size Filter - HEPA or High Efficiency filter
Cyclone Dust Collection Kit for DeWalt Planer
Starting from scratch? Select one of the full kits below to order everything you need.
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.