Festool Plug-It adapter for DeWalt sanders

The change is reversible. Fits DWE6411, DWE6423 and other variations.

The model has tight tolerances so you printer and filament should be well calibrated. Also it requires a bit of sanding or cutting to achieve a good fit. It's not possible to make a good fit part for injection molded tool frames - they vary a bit, so grab a sharp knife and a small file and make it fit perfectly.

BOM:

• Festool replacement part # 489742 or # 489925 or whatever number you find it
• Two M4 12mm bolts

Printing settings:

• PETG
• 0.2mm layer height (the model is optimized for this layer height)
• 4 walls
• 100% infill
• Manual tree supports (please see photo of surfaces which needs to be painted/supported)

Installation instructions:

• Disassemble the tool, disconnect and remove the cable
• Dry fit the model, adjust it when needed to ensure that it fits snug but doesn't push the frame apart
• Insert Festool part. Once you insert it you won't be able to easily take it out.
• Screw the bolts, there are no threads in the model so the bolts will be tight
• Trim the cables and crimp them if the cables don't fit well (for DWE6423 they were too long so I had to trim them)
• Connect the cables
• Screw in the connector
• Assemble the rest of the tool

Similar design for Plug-It connector for DeWalt sanders, implemented from scratch with tight tolerances.