Turns out they can EXPLODE?

Here are all of the dust collection chutes I currently offer:

These are the Bosch Axial Glide dust collection chutes as featured:

I hope this video is helpful (or at least entertaining!) for anyone attempting to solve miter saw dust collection in their shop. These saws are powerful and small offcuts can pack a serious punch under the right circumstances. It is our job to make sure that we don't put the saws in this position! Stay safe out there and happy building

Interested in 3D modeling or 3D Printing? Learn Fusion 360!

Links to Referenced Products (some are affiliate links which help sponsor the content!):
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Shop Nation Links:
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#mitersaw #dustcollection

[ShopNation]

FYI, this product has been redesigned (GEN 2) to DRAMATICALLY reduce the liklihood of this happening. I'm always looking to improve and appreciate any and all feedback!

[andrewmetts]

I just installed your dust chute on my Bosch Glide Miter Saw today, and found a link to this video in the package. I like your systematic approach to both development of the original product, and attempting to re-create conditions that caused failure. Great videos! I've been woodworking for about 50 years now, and I've had a few mishaps that would have thrown small pieces into your dust chute if it had been there. 1. Cutting small pieces against a stop. If you hold the saw blade down and allow the blade to stop turning you're OK; but if you raise the spinning blade while the small offcut is trapped against the stop, the extra thickness of the teeth will sometimes lift the end of the offcut until it becomes pinched between the blade and the stop, much like tablesaw kickback. That gives the blade the traction needed to launch the offcut violently. 2. Even without a stop, a wedge-shaped offcut resulting from a sharp miter becomes pinched between the fence and the body of the spinning blade. All is well until you raise the blade, and the wedge shape gives the teeth the traction to launch the offcut. Hope this helps you or somebody else. Great job!

[Gatewaybuilds]

Thank you for showing and addressing product “issues”. People often don’t realize how much time and effort go into product development and testing, so your transparency and honesty is staggeringly refreshing. Keep it up!!

[ChadsCustomCreations]

Love these product development series you’re doing, the full transparency is very honorable.

[joshkendrick]

Also, dull blades might make it easier to throw a piece as well. When the blades are dull, they are tearing through the wood as opposed to slicing it. I would expect it to be more likely to impart more force into the piece as you cut.

[bgregt]

Mine blew out when I was cutting a short piece of 1x2. Fortunately I use a third hand for just such situations. Never thought about requesting a replacement because it was my mistake. I just collected all of the pieces and glued them back together. Filled the missing gaps with epoxy. The design is good.

[LeighHart]

@ShopNation Hi Travis, just installed my brand new v11 on my Bosch glider. First cut to test the dust collection was on a length of a 1x1.5” piece of pine; about 1” wide. It blew out the back on the first cut without even lifting the blade back up again. 😢. Entire right side of the chute was blown to bits.

I’ll drop photos to the support mailer but wanted to make mention that I wasn’t cutting like a madman; the piece was lying flat not standing up; blade is basically brand new 80 tooth crosscut and dust collector is a 5hp shop vac.

[alantran]

DeWalt had a recall on their saws for the same exact issue. The factory plastic piece was blowing up/shattering. The new recall repair kit is a stamped steel version .

[jeffwimer]

Your dust collection adapter has been a game changer. It has greatly diminished the amount of dust that comes off of each cut. Thanks for sharing this update.

[halsti]

one way to get a high chance of kickback on mitre saws is to use a stop block on the off cut side, then raise the blade while its still spinning post cut. that basically blocks the off cut between the blade and the stop block and shoots it out.... just in case you ever need to test stuff like that again.

[ryanreuter]

I bought a delta cruzer yesterday based on your video. Immediately ordered a chute for it. I've got full confidence in your stuff because of your approach on these videos. If you make a new version that's better, I'll buy that one too. Thanks man.

[pambenziger]

Thank you, Travis, for being so open and honest. I purchased your digital plans for my Ridgid miter saw and it has made a HUGE difference in the amount of dust in my shop. As a novice woodworker, I sincerely appreciate the heads-up and safety warning. I've also learned a lot just reading through some of the comments, here, so thanks to you experienced woodworkers, too! (I just built my miter saw station and added a fence just so I could use stop blocks for repeated cuts...but now I know not to use a stop block when cutting small pieces.) Thanks again!

[craigfehr]

Great video, thanks Travis!
I was one that had a chute explode and I promise I wasn’t cutting like a lunatic 😂.
My scenario was just a single cut (so no build up of offcuts), and the only time it got violently sucked up was when I did an angel cuts (22.5 degrees) on edge. Otherwise had no issues at all. Will definitely try the “zero clearance” fence trick tho.
Worth mentioning too was the great customer service I received when I reached out. 👍

[JeffreyMoon]

As an engineer, I appreciate the process you followed to duplicate the failure. Something you've discovered is that some users will push the limits of the tool. Others just don't follow proper technique. You can break almost any tool if you aren't careful. FWIW, I've had my dust collection chute installed since September and I've had no issues thus far.

[scottgates]

As a carpenter and long-time miter saw user, I have some thoughts to consider. The type of kickback you are seeing happens when the off-cut gets punched between the blade and something else. The pinching is usually necessary for the saw tooth to get enough traction on the part to transfer enough energy to cause that much acceleration. It can get punched against something rigid, like the fence. Or it can get punched against something soft like the rubber dust boot. Without the pinching, the off-cut just usually just moves out of the way a little when the saw tooth makes contact. Leaving many small pieces in a confined area certainly increases the likelihood of pinching. However, a single piece can definitely pinch against something and become a projectile. I have done it many times. For me, that is usually because my off-cut is slightly smaller than the gap between my blade and fence. That is one of the ways the zero clearance fence helps. The kickbacks that I experience, as well as the ones that you duplicated, can be reduced by operator awareness. First, keep the cutting area clean, as you suggested. Second, be aware of the off-cut size and potential spaces that it can get pinched and bind against the blade. I would question the idea of making a dust collector strong enough to not break. The rotational energy of the blade is very high at that RPM. Your kickback examples blasted through that plastic with almost no effect on the blade speed. Imagine if that off-cut had no place to exit and was forced to stay bound against the blade until all of that energy was absorbed. I think something more catastrophic would happen. Possibly blade damage or even damage to the spindle, bearings or aluminum housing. Maybe giving the off-cut a way to exit sooner or easier would be a consideration. I hope this helps.

[mikeh]

I resin printed mine and have been using it for a few weeks. It works wonderfully!

I have not had any shooting pieces, and definitely no blowouts.

Keep up the great work!

[alexanderdavis]

There is a story about Henry Ford when designing the engine for the Model T. He had an issue with the engine block cracking. His engineers told him to make the metal harder. But he decided to go the other way and make it softer. This gave the block a little flex and solved the problem.

[mrlebowski]

My first one exploded with one quick cut ( I should have taken more time) off a 3/4" piece of plywood. I had been using it for a few weeks with no issue. I never let anything pile up on the saw so I think it is just something that can happen when you cut small pieces. I ordered a second one because the product does a great job ( I paid full price, no complaints) but I had already decided to add the fence before I use it again.

[defensivecyberllc]

Same thing happened to Dewalt Miter Saws.. they switched back to metal from plastic. They did offer free replacements/fixes though.. as the liability from the "explosions" is something you should be aware of.

[BLBlackDragon]

As someone who has been 3D printing for over a decade, I have a materials recommendation.
Rather than using PETG, which is fairly brittle, you might try ABS or ASA.

You will need to enclose your printing cabinets to increase the ambient air temperature (and maybe add a heater).

ABS is an engineering grade material, with a little more elasticity than PETG.