When it comes to dust-making power tools, my table saw is probably one of the biggest culprits. And besides making a mess, woodworking dust is something I want to keep under control in the shop.
The problem is that many table saws — particularly contractor-style and benchtop models — have large openings throughout the cabinet. Instead of pulling air and dust toward the dust-collection port, those openings allow air to enter from all directions.
Fortunately, you don't have to completely rebuild your table saw to improve its dust collection. A few inexpensive modifications can close the biggest gaps, help contain chips and dust, and direct more of them toward your dust collector.
Here are four places to start.
1. Close the Back of a Contractor-Style Table Saw
One of the largest openings on a contractor-style table saw is at the back of the cabinet. Unfortunately, it's also one of the trickiest to seal.
The motor, belt, blade guard assembly, and other components may extend through this area. So you can't simply screw a solid panel across the back.
My solution is a removable panel made from 1/4" plywood.
I cut the plywood panel to fit the back of the saw, then added notches and openings wherever necessary to clear the motor, belt, and other components.
Rather than permanently attaching the panel, I recessed strong rare-earth magnets into each corner. The magnets hold the plywood securely against the metal cabinet while still allowing me to remove it whenever I need access to the saw.
There is one limitation to this particular setup. The panel only works when the blade is positioned at 90° to the table. Since that accounts for most of the cuts I make, however, it's still a worthwhile improvement.
Why Sealing the Cabinet Helps
The goal isn't simply to keep sawdust from escaping through the back of the saw. Closing the large opening also gives you better control over airflow inside the cabinet.
Instead of leaving the entire back of the saw open, you're helping contain the dust and chips so they can be collected from another point in the cabinet.
2. Seal the Blade-Tilt Slot With Foam
Once you've dealt with the largest openings, take a closer look at the smaller gaps in the cabinet.
One obvious spot is the curved slot that allows the blade-height mechanism to move as the blade tilts.
To narrow this opening, I apply a sheet of self-adhesive foam to the inside of the cabinet. A slit cut into the foam allows the mechanism to move while the surrounding material covers much of the otherwise open slot.
The foam is inexpensive and easy to cut. The original version of this tip used self-adhesive foam sheets available from an office-supply store.
It's a small modification, but when you're trying to improve dust collection, sealing several small openings can make a noticeable difference in controlling airflow.
3. Fill Small Cabinet Gaps With Foam
There are usually a few more openings worth addressing, including the narrow, irregular gaps where the table saw cabinet meets the underside of the table.
These aren't always convenient places to attach a rigid panel.
Instead, I use foam pipe insulation and foam backer rod.
Both materials are easy to cut to length and compress enough to fit into irregular spaces. Simply trim a piece to fit and press it into the opening.
The advantage is that you can seal an awkward gap without permanently modifying the saw.
As you close these openings, however, remember that you're trying to control airflow, not eliminate it completely. Your dust collector still needs replacement air entering the cabinet in order to carry dust toward the collection point.
4. Add a Dust-Collection Hood Below the Saw
Closing the gaps helps contain the dust, but that's only half the job. You still need a way to remove the dust and chips from the saw cabinet.
Many contractor and benchtop table saws have another large opening at the bottom.
On a job site, that's convenient because sawdust can simply fall through the bottom of the saw. Inside a woodworking shop, it's a recipe for a pile of dust underneath the machine.
A simple solution is to install a plastic dust-collection hood inside the bottom of the saw cabinet.
These hoods are shaped to catch falling sawdust and chips. A fitting in the center provides a connection for a 4"-diameter dust-collection hose.
Now you've created a more complete system: The panels and foam help contain the sawdust while the lower hood provides a place for the dust collector to pull it out of the cabinet.
Don't Completely Seal Your Table Saw
There's an important distinction between containing dust and making the cabinet airtight.
A dust collector works by moving air. If you completely seal every opening in the table saw cabinet, there won't be enough incoming air to carry dust and chips toward the collection hose.
The goal of these modifications is therefore to close the large, uncontrolled openings and better manage the airflow through the saw — not eliminate airflow altogether.
You also need to make sure none of the modifications interfere with the saw's motor ventilation, belts, blade-tilt mechanism, blade-height adjustment, or other moving components.
After making any modification, operate all of the saw's adjustments with the machine unplugged to verify that everything moves freely before turning the saw back on.
An Inexpensive Table Saw Dust Collection Upgrade
You don't necessarily need an elaborate dust-collection system built into your table saw to make an improvement.
Start with the largest openings. A removable plywood panel can close much of the back of a contractor-style saw. Self-adhesive foam, pipe insulation, and backer rod can take care of smaller gaps. Finally, a dust hood beneath the cabinet provides a collection point for a 4" hose.
You can use one of these ideas or combine several of them. Either way, a few low-cost changes can reduce the amount of table saw dust that ends up throughout your shop — and make cleanup a whole lot easier.
