Thank you for your purchase!

Before we dive into the download and instructions one thing that should be noted is that I use a major and minor revision system to track changes that I make and test on my machines. Example v3.7.2 the 3 signifies the 3rd major change to the model, the 7 is a minor version change to the model, the 2 is a small tweak in this case printer settings in Prusa.

What the versions mean to you is that inside the download folder there is set of STL and 3MF files that have been extensively tested and have been run on my Prusa MK3S+, Prusa MK4, and Bambu X1 Carbon printers to ensure the best printing experience for you.

When you open the download you will have to extract it to find the following files;

• Dust Boot replacement for dust shroud

  • DW735 Boot v3.7.2 Part A

  • DW735 Boot v3.7.2 Part B

  • DW735 Boot v3.7.2 Part C

• Exhaust Port Cap

  • DW735 Dust Port Cap v3

• Safety Override Switch

  • DW735 Safety Switch v1

The STL files are directly exported out of PrusaSlicer and the 3MF files were generated using PrusaSlicer v2.7.1 win64.

A little bit about my machines. The Prusa machines are all located in original Prusa enclosures and are located in a cooler section of my shop and in winter (when these files were generated) I adjust the temperature of the filament up 5°C to compensate for an ambient room temperature of 65°F. In the summer I will leave settings stock as the room generally sits at 70°F.

I have found that printing left to right with the opening of the Boot to the right produces the best print on my machines even with an enclosure.

The only print needing supports is the exhaust port cover. If you use the 3MF file the supports have already been painted on

I print these parts exclusively using PETG filament and have found Prusament and Polymaker to work really well. Here is a link to a YouTube video comparing filament results.

For the boot and safety switch all bolts come directly from your DW735. If you choose to cut the top of your cover, you will not need the safety switch and bolt extender, but hold on to them because you never know if you will need them.

If you do choose to cut your cover, you will need a 4 inch or greater hole saw for this and you will measure from the back and left-hand side facing the unit with the cover removed. (see page 2 photos). This information can be found in our YouTube assembly and installation video (link below) at the 13:21 mark. Measuring from left to right you will find 7-1/16th inches to mark and then from back to front you measure then mark at 6-9/16th inches. One change to note from the video is that I ran the drill in forward motion, and I have heard from others that going in reverse will produce the same cut without the hole saw biting, binding, and grabbing.

A note that customer Derek B. advised if you change the right to left measurement to 7-3/16th inch you can hit a perfect 4” circle. He used a 4” Blu MOL Xtreme QuickCore Carbide hole saw to make his fit perfectly. I am a fan of oversizing the hole a bit to allow for deviations, however I wanted to pass this information along.