I replaced my bandsaw’s wimpy 1-1/2-in. dust-collection port with a shop-made shroud that makes bandsawing virtually dust-free. The secret: My shroud’s intake port is much larger (see photo and exploded view, below). Another great feature is that the big hose mounts on the back, so it’s out of the way.
I built this shroud by improving a similar design I’d seen in an old woodworking magazine. My shroud is mounted on a steel plate that I cut to size with my angle grinder (1/4-in.-thick plywood would also work for the mounting plate). I attached this plate to the saw’s casting, using the same tapped holes that held the original port. On saws without a port, you’ll have to drill and tap a couple holes in the casting.
The shroud’s angled top allows the table to tilt. I sawed the back plywood face to match the profile of the saw. I left the front face as wide as possible. It actually extends inside the door and is cut to fit around the wheel.
I cut a 4-in.-dia. hole in the back face and installed the sheet-metal duct. Then I attached the faces together with a length of 22-gauge galvanized sheet metal. The lip at the bottom helps keep sawdust in the shroud.
Once the shroud was mounted, I marked and cut the saw’s lower door, so it would close. I was reluctant to alter my saw by cutting the door, but I’m glad I did. This shroud makes bandsawing much cleaner and more enjoyable.