I have been wanting a Kapex (and the clean shop that I knew would follow it) for several years. I finally took the leap a few months ago and bought it. I wanted to integrate it into the shop cabinets that I was about to build, so I bought it just before cabinet construction began. I wanted to incorporate a space for Dust Extractor into my plans. I am sure that many of you have done similar things and I wasn't smart enough to join FOG first and look at other's ideas. Day one.



I wanted the Kapex to recess into my countertop so I had support on either side the saw for long material. Even though the Kapex with a CT33 extractor creates very little uncaptured dust, I knew some still got away– I had seen the Kapex in action at my Woodcraft store, and there was a pile of dust behind it. So I set out to incorporate a downdraft table under the Kapex in my design. So here is what I came up with.



I have a ClearVue Cyclone 5hp system in my shop, but even with that power, I knew the velocity had to remain high for the downdraft table to be effective. I made the area small and shallow, concentrating on the back 2/3 of the table. I decided 3" in the center, tapering to 0" at the very edge. Why did I choose these measurements? Just sounded about right…
A closeup to the internals of the tabletop. I put a standard 4" port in the bottom to facilitate connection to the cyclone.



With more of the construction complete, you can see how the plumbing connects. I have a blast gate above the countertop so I can shut off the airflow when using other tools. Notice the Dust Extractor "garage" next door. I painted inside the garage black so it would just "disappear" in the front of the white cabinets. I ran wire and put an outlet in that area so the extractor cord can remain almost totally rolled up on the back of the unit while in use. No cords running across the countertop.



I put grommets in the sidewall of the cabinet to allow for quick removal of the cord and extractor hose for use with other tools.



By this time I am able to use the saw in place to aid in constructing the cabinets and countertops that support it.



So after a little use, swapping back and forth the extractor hose to other tools, I decided that was getting old. Dust collection was good, but it was a hassle. I started playing around with connecting the Kapex to the unused port on my blast gate. I had to tinker with hose sizes, but found a premium 2-1/2" hose about 24" long gave me the volume as well as the velocity to evacuate the Kapex–and it worked even better than the CT33 extractor. I mention premium hose here because I tested several sizes and lengths and used cheap hose to test with. It simply didn't work. It would collapse when the cyclone was turned on. I arrived on this hose setup and now, I no longer have to move the hose back and forth through the (now sealed) grommet. This photo was taken after I made all of the crosscuts for my door frames. Dozens of cuts and no dust left on the table! The downdraft is picking up everything that gets past the hose. I am crosscutting almost 100% dust-free!



I used a piece of pegboard as a template to mark the holes for the downdraft tabletop. I taped it in place and misted black paint from a spray can over it. That showed up well on the white countertop. I then drilled 1/8" pilot holes, then drilled 3/8" holes and then used a countersink bit to bevel the holes–all 429 of them. Yes, 429 holes, drilled three times. That was a lot of drilling…

If I were doing this project over again, what would I change? Only one thing. I would expand the downdraft area another two inches forward on the table, maybe three rows. The dust I do see accumulating is in that area. Nothing in the back and nothing in front of that area. Otherwise, I would build it over again exactly as it is.

If you have any questions about what I did or why, feel free to ask. I will answer to the best of my ability.

Very nicely done.

Now cut a couple of T-tracks into your bench, and them mount the Incra Track and stop.





Mine is set up like this:

Thanks Brian. Feel free to plagiarize away!

I tried every conceivable contraption behind the blade, including a two-piece hood with two 4" hoses running to it. I just could not get anything close enough (without interfering with saw function) to make a difference. It just didn't help. The downdraft does not interfere with anything and does an excellent job. This setup lets me cut very clean.

After reading Bill Pentz's writings a few years ago, I got serious about getting the dust out of my shop. This setup goes a long way in accomplishing that.

http://billpentz.com/woodworking/cyclone/index.cfm

I have friends who scratch their heads when I say I want better dust collection than a Kapex and a Festool dust extractor are capable of. They just don't get it. The folks at my local Woodcraft don't understand that when I say I want dust collection, I want it all collected. Out front on the sales floor, they tout how clean the Kapex cuts. But behind the Kapex in their classroom is a big pile of sawdust. Around every tool in their classroom is a big pile of dust. I showed them pictures of my setup and told them how clean it really is. They shrugged. There have to be more people out there who want to cut really clean…

Nice  set up. Like the clean neat install. Downdraft looks great, but that is a lot of drilling. I wonder how it would work out to use Domino slots instead of drilled holes?

I need to redo the miter saw wall in my shop and get the Kapex installed semi permanent.  Your design is pretty close to what I need.   


Seth

one more question for ya... what is that clear plastic Y fitting you have both hoses coming off of?? Is that some sort of manifold you bought, or is it just shopmade? 

My cabinet construction is a bit simpleton compared to yours, but here is my take on your great concept.



Instead of the pegboard holes I used some 2.5" and 3" holes. I drew an outline of the kapex footprint, and concentrated the holes where the kapex base wasn't.  Then I just sandwiched some 1/4" wire mesh between a layer of 1/2" ply underneath.   Picture isn't great but I also gave a little rounding to the front of the cabinet since in the past I have tended to jab myself in the kidneys with miter saw handles...



Upgrading my DC at the moment (got a cracked body CV cyclone, sigh), so haven't really gotten to put the downdraft to the test yet.  Just using the ct36 so far.
But the fence and kregstops I put on the left have been working out really nicely.



Full 6" port. I am planning on running a 4" hose into the cabinet on either side, which will Wye into the 6" port.

Also before I put the downdraft into commission I should probably use something other than duct tape for the angled sides   Also want to route a roundover into the port to make it a mini bellmouth. I can picture that helping alot.

Yea the mesh keeps most small screws and things like that from falling in which is nice. I initially tried some window screen material I had lying around, but it was just way too restrictive for wood chips to get through. I've only briefly tested this mesh using my incredibly underpowered HF2hp DC (using a long 4" flex hose to make it worse), so I wasn't able to feel much suction, but it got everything that went near holes still.  Can't wait until I get a new cyclone body to get it installed as I have almost everything else ready.

I put some T-track on top of the cabinet to the left of the saw and used T-nuts in there going through the back part of my "fence" secured with T-knobs. In this way, I can adjust the fence a bit, and slide it forward if I ever add a subfence to the kapex. The T track also lets me slide the fence all the way back to the wall if I ever need to desperately get more countertop space for any reason. So far love the stop, it has proved useful many times. Even when cutting smaller parts than the distance from stop to blade it can still be used with a spacer (aka, piece of scrap).



The awkward space I have to the sides of the kapex cabinet will eventually have the 4" hoses in the back, and then I'll be adding some small shelves for cutoffs to fill the space so hopefully it looks a bit less Frankenstein when all is done.  Also I have a door to put on it eventually too.  Oh yea and you might notice my wood central inspired acrylic table saw blade guard is also ready to go into commission soon. Almost all of it was made with the kapex and the compound miters came out dead on.

Nicemac,
I absolutely love your setup.  do you have any sketches with dims of your Kapex cabinet?

This is one of the best workstation threads I have seen with the Kapex.  If I ever get to a point where I can permanently mount the saw, this is a thread I will turn to for some inspiration.

Scot

Quote from: ictusbrucks on June 23, 2012, 03:29 PM

My cabinet construction is a bit simpleton compared to yours, but here is my take on your great concept.

I'm trying to get around to starting my MFT and KAPEX workstations and have been reviewing my old notes. I've found quite a few images I'd saved at the time, so where I can, I'm trying to add them back in to the threads where the photos were previously lost.

Hope someone finds this useful and that it's OK with the original authors.

GarryMartin ,
How does your set up work out?  Does it grab all the dust?  Trying to decide whether or not to bite the bullet and just drill the mini-holes.

GarryMartin ,
How does your set up work out?  Does it grab all the dust?  Trying to decide whether or not to bite the bullet and just drill the mini-holes.

It's not my set up - I just added some photos back in to the thread. The Kapex station is by @nicemac

Took this pic tonight without cleaning up… I would not change a thing since my original design!

So the downdraft table is connected to your main DC, but the Kapex is connected to your Rigid shopvac? Just trying to understand. I'm in the middle of designing my own Kapex miter saw station and I like the idea of the downdraft table, but I want it to be something my Fein turbo can gobble up rather than turning on my big 5hp central cyclone every time I need to make a three second cut.

 Thank you for the kind words.  I installed a remote for my dust collector and mounted it on the manifold  just to the left of the machine.   I routinely use it just for a single cut, even if it’s only for a few seconds. I’ve been doing it for years. I see no harm in doing that.  I have the five hp  power Clearvue cyclone with a big impeller, and don’t feel like you could get away with a much smaller system to thoroughly clean the area around the Kapex.   That downdraft table requires a lot of suction. 
 Yes, I installed a T track to the left of the saw just for consistent repetitive cuts. I debated doing it on both sides, and saw no real value but bought the track  in case I needed it. I never installed it, and gave it to a friend.  I’ve never felt like I needed a sliding fence, I just use the fence on the Kapex itself.