A table saw creates plenty of sawdust, but collecting it can be especially challenging on contractor-style saws. Unlike an enclosed cabinet saw, these machines often have large openings around the motor, adjustment mechanisms, and underside of the table.
Those openings make it difficult to contain the dust and chips inside the cabinet.
One way to improve the situation is to close some of the largest gaps. You don't need to make the saw airtight. Instead, the goal is to reduce large, uncontrolled openings and better manage airflow through the cabinet.
Here are four inexpensive ways to do it.
1. Close the Back With a Removable Plywood Panel
The large opening at the back of a contractor-style table saw is the obvious place to start. Unfortunately, the motor, belt, blade guard, and other components can make it difficult to simply cover the opening.
The solution shown here is a removable panel made from 1/4" plywood.
Cut the plywood to fit the back of the saw, adding notches and openings as necessary to clear the components that extend through the cabinet.
Instead of permanently fastening the panel to the saw, recess strong rare-earth magnets into its corners. The magnets hold the panel against the steel cabinet while still allowing you to quickly remove it.
There's one limitation to this particular design: The panel is intended for cuts with the blade at 90° to the table. For a bevel cut, simply remove the panel so it can't interfere with the saw's moving components.
2. Seal the Blade Adjustment Slot With Foam
After closing the large rear opening, look for smaller gaps where dust can escape and uncontrolled air can enter the cabinet.
One of these is the curved slot that allows the table saw's adjustment mechanism to move as the blade tilts.
A piece of self-adhesive foam provides a flexible way to narrow this opening. Apply the foam to the inside of the cabinet and cut a slit where the mechanism passes through.
The slit allows the mechanism to travel while the surrounding foam covers much of the open slot.
Because the foam is flexible, this is an easy way to close an irregular opening without interfering with normal adjustment of the saw.
3. Fill Irregular Cabinet Gaps With Foam
Another place to check is where the table saw cabinet meets the underside of the cast-iron table.
These openings can be narrow and irregular, which makes covering them with plywood or another rigid material difficult.
For these areas, foam pipe insulation and backer rod offer a simple solution.
Both materials can be cut to length and compressed into an irregular opening. The foam conforms to the shape of the gap and stays in place without requiring a permanent modification to the saw.
This also makes it easy to remove later if you need access for maintenance or adjustments.
4. Use a Sheet Magnet to Cover Smaller Openings
For openings in a steel cabinet, a flexible sheet magnet provides another removable solution.
John Cusimano of Lansdale, Pennsylvania, uses a large sheet magnet to cover the slot in the front of his table saw. The magnet sticks directly to the cabinet, so there's no need for screws, adhesive, or a permanent modification.
You can trim the magnetic sheet to fit the opening and remove or reposition it whenever you need access to the saw.
It's an especially handy approach for an opening that doesn't need the more substantial plywood treatment used at the back of the saw.
Don't Make the Table Saw Cabinet Airtight
Closing gaps can help with dust collection, but the objective isn't to completely seal the cabinet.
A dust collector needs airflow to carry sawdust and chips through the collection hose. If you block every source of incoming air, you can work against the system you're trying to improve.
Instead, concentrate on reducing the large and poorly positioned openings that allow dust to escape or make airflow difficult to control.
Also make sure any panel, foam, or magnetic cover stays clear of the motor ventilation, belt, blade, trunnions, and blade-height and bevel mechanisms.
After making a modification, unplug the saw and move the blade through its full height and bevel ranges to make sure nothing interferes with the mechanism.
Take the Next Step: Improve the Entire Dust-Collection System
Sealing cabinet gaps is just one part of improving table saw dust collection. You still need to capture the dust and move it out of the saw.
Want to capture more of the dust once you've sealed the cabinet? See our complete guide to How to Improve Table Saw Dust Collection: 4 Simple Upgrades for adding a lower dust hood, connecting a 4"-diameter hose, and improving the overall collection system.
Together, these approaches can help contain more of the sawdust at its source rather than allowing it to spread throughout the shop.
