I'm sure others have done this but I couldn't find an example of what I needed. This under table dust collection box is for the Bench Dog cast iron extension, Bench Dog 40-016 ProLift and PC 7518 router motor -- all attached to a right tilt Unisaw. I got the idea from Jim Becker's post of a similar box installed on his slider. Also thanks (I think ) to Bruce Page for his recent "Dog is in the House" post which started me down this slope. I also found a nice design by Glenn Bradley who essentially built a router table cabinet under the extension. However, I actually use the floor space under this box when I slide my bandsaw next to the tablesaw. Search "bench cast iron extension" to see other posts including pro/cons regarding table saw router table extensions vs stand-alone tables. Saving floor space is the deciding factor for me so I'm selling my stand-alone table now that this project is finished.
The main design problem for the Unisaw is fitting the box around the blade tilt wheel. My low tech solution is just to make the box easy to remove when I need to tilt the table saw blade (I rarely tilt the blade from 90 degrees anyway).
Key construction/assembly points (or things I didn't think of initially):
- Use 1/4X20 threaded rods (with Loc-Tite) into the CI extension and large knobs to make it easier to install/remove the box. Add 1/4X20 couplers on the end rods to continue to use the provided router fence hanger hooks.
- Box dimensions are ~9" X 13.5" (~ fit to the CI extrusions under the plate insert) X 20" tall (includes space for 15 degree dust collection ramp and a small shelf on the bottom for insert rings, height adjuster, wrenches, extra collets, etc.). Box is attached using 22" long 3/4X2.5" runners.
- Add a 4" dust collection fitting and a cord grommet with snap in fitting to make it easier to remove the router. Cut several 45 degree slots opposite the dust fitting to ensure sufficient dust collector air flow.