Enhancing the DeWALT DW735 Planer: My Journey and Game-Changing Dust Collection Solution
In 2019, I began my journey to upgrade my DeWALT DW735 Planer. It started when I needed new knives after damaging one. During my search, I discovered Byrd Tool's Shelix cutter head. This was a revelation, highlighting the benefits of upgrading to a carbide-tooth cutter head. I chose the OEM size for simplicity.
The Shelix cutter head transformed my woodworking, improving cuts and eliminating concerns about wood grain direction. Years later, I’m only on my third blade rotation, despite processing thousands of board feet. However, I encountered a new challenge: limited material removal per pass. The cut depth was significantly reduced, causing frustration and prolonging the planing process.
With two 3D printers at my disposal, I decided to tackle the problem myself. The DW735, although well-designed, struggled with the chip volume, burdening the motor. My goals were clear: reduce motor load, decrease motor heat, and increase cut depth.
I dived into Sketchup to design a new dust shroud, bypassing the motor's chip extractor. After several prototypes, I developed a functional design that met my needs. Although effective, it was initially challenging to install and remove.
Through multiple iterations, I refined the design. Now at version 4.2, printed in PETG for durability, my dust boot is optimized with 23 incremental improvements. It solves the initial issues and enhances installation ease, transforming my DeWALT DW735 into a production-ready machine capable of continuous planing until the dust collector is full.
Additional enhancements include new mounting screws to prevent finger slippage, a blower for a refreshing air blast, and a dust port cover to ensure safety with kids in the shop. I drilled a 4" hole in the cover for component concealment and designed a magnetic coupling for quick hose connection and stowage. A red safety cap covers the cutter head hole when the hose is disconnected, and a magnetic ceiling mount stows the hose out of the way.
I’m thrilled with my DW735’s performance and foresee no need for further upgrades soon. Yet, my DeWALT planer will always be a staple in my shop due to the thought and effort invested in solving these issues.
If you’re looking to enhance your DeWALT DW735 Planer, you have two fantastic options: purchase the fully assembled dust collection kit or download the digital files to print it yourself. Transform your planer into a high-efficiency machine and enjoy smoother, more efficient woodworking sessions. Visit our shop to get started today—your machine and wallet will thank you.
~ BuilderDadDan