I have been cutting mostly aluminum for years on my CNC Routers. Back in 2016 I wanted to start cutting more wood and MDF which generates substantially more dust. So I designed a dust shoe and a cyclone separator. The dust shoe is available in a few configurations for both 65mm and 80mm spindle OD. The cyclone works better than I could have expected. Aluminum chips and wood dust are easily seperated to avoid face loading the shopvac.

The Cyclone is designed to be easy to reproduce using off the shelf hardware store parts like 2" PVC elbows, 1/4" plywood, threaded rod, etc.

I also have the native Solidworks models for each part and conversions to STEP included so you can modify the models to fit your needs. I also have the DXF profiles for the wood piece's inside the cyclone.

Parts:

Parts for the Dust Shoe:

• Qty:20 = 8mm OD x 3mm thick neodymium magnets. They can be bought on ebay, aliexpress, or even your local hardware store for a couple dollars.
• Qty:8 = 3mm bolts, or small screws to hold on the lower boot.
• Qty:2 = 5mm nylok nuts.
• Qty:2 = 5mm bolts to clamp the upper section on the spindle and around the shopvac hose.

Parts for the cyclone separator are:

• Qty:2 = 5 Gallon Pails (the top one cut off 3" into the lower bucket).
• Qty:1 = 5 Gallon Pail Lid.
• Qty:3 = 2" Pipe Elbows.
• Qty:1 = 2" Connection Union.
• Qty:2 = Short Sections of 2" pipe.
• Qty:2 = Small Pieces of 1/4" plywood cut to size on the supplied DXF.
• Qty:2 = Section of 3/8" threaded rod.
• Qty:8 = 3/8" Nylok Nuts.
• Qty:8 = 3/8" Washers.