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Remake of Dewalt 611 Air Diverter

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General Information

Air diverter and dust shoe for Dewalt 611. I carved this out of a .5" thick Natural HDPE as a test. The carve took about 4 hours with a 1/8" bit. The vacuum adapter is a Rigid Universal Tool Adapter VT1407 available at Home Depot. Lowes also sells the adapter #37045

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Material Description Price
Natural HDPE Sheet

Natural HDPE Sheet

Dimensions: 8 in × 12 in, Thickness: 1/2 in, Type: Single color, Color: White

File Description Unit Price



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from Inventables


set up in easel

open in easel and make sure all your settings are correct

Easel setup:

When you open this in easel please make sure and check all your settings as mine may not work for you

Saftey Height: 3mm
Step over: 40%
Feedrate: 25 in/mm
Depth of cut: .028
material thickness: .500"

I changed the vacuum adapter hole to a fill operation this added time but it will make sure that the adapter fits correctly

Also the collet hole needs to be enlarged to fit the Precise Bits Dewalt collet for using .125" bits
I enlarged the hole to 1.210" and position the circle on center to x= 2.494" and y= 2.497"

Then I added 6 holes to the left side of the piece for mounting of a brace that connects to the Inventables spindle holder accessory holes I haven’t really finished this design so I am hoping that the holes will work they are spaced .5" edge to edge from each other

This took along time to cut out I actually did it over 2 days by pausing the machine turning off the spindle and then coming back to it.

I really didnt think that it would turn out right due to the way that it was cutting Easel uses very very inefficient tool paths to cut this out a better option might be to use Fusion 360 or something but in the end it did work

This is a remake of a dust guard that is already on here and its hard to tell from the pictures but when using .5in material alot of the time is taking the entire top surface down almost .125 before it actually cuts anything that resembles anything I believe if you have a planer or belt sander you can reduce the thickness of your material and your cut will go alot quicker I believe why the original was done like this because you cant commonly buy material the correct size and due to the original being made out of a cutting board this saves money but not time

You could probably using a surfacing bit and set easel up to plane down your wood in much less time than using a .125 bit to do it

hope you enjoy it does look like it will work very nice on the X-Carve though


Clamp the material

I cut some spiral clamps and used 8 of them to secure the piece on all sides to the table with a .125" spoil boards



240 minutes

Alright folks this will take awhile but cut the piece and go have a beer



Clean up the little plastic stragglers and admire your finished piece


With adapter

adapter in the piece