This adapter allows connection of a 2.5" dust collection hose to the top of a Shopsmith Mark V 510, 520, or Mark 7 upper saw guard for overhead dust collection. Based on the concepts and ideas of William H Seward IV. Many thanks to William on his generosity towards me, and the greater Shopsmith community.
Requires cutting a hole in the upper saw guard to allow airflow.
Mounts using the existing 3/16" through-hole of the upper saw guard. I've not been able to find a smooth 3/16 pin of the correct length. A #10 machine screw fits just fine. Just be sure to use a Nyloc or similar nut. The adapter fits snugly enough that no gluing or sealing should be necessary. There is a mounting hole at the nose of the part, but it has not proven to be needed.
As an alternative to a #10 screw, there are many ¼" smooth pins available at the typical US hardware store. I've included a version with a ¼" hole. However, this will require drilling out both the plastic guard, as well as the metal support bar. The files for this version are named “Shopsmith Overhead Dust Collector 0.25”
For a 3/16 pin or a #10 screw, print “Shopsmith Overhead Dust Collector”
UPDATE: On request I've added versions that require no supports. File names should make it clear which is which.
Printing: I suggest PETG, ABS, or ASA. Tolerances are tight so ABS / ASA shrinkage will need to be taken into consideration. Print with the hose connection DOWN, and with supports on the build plate only. An inner and outer brim will help as there is not a lot of contact area for the size of the print. Standard infills of 15 or so percent are sufficient, but I would either add a couple perimeters or print with a 0.6 nozzle.
The author marked this model as their own original creation.