Dewalt Trim Router Tool Slide for Festool Track with Dust Extraction

This custom-designed tool slide integrates a Dewalt Trim Router Plunge Base with a Festool track, allowing for precise and adjustable cuts along the track’s length. This design is perfect for cutting custom-width grooves by adjusting the back-and-forth movement of the router. For instance, using a 1/2" router bit, you can accurately cut an 11/16" groove by setting the tool slide’s stop for exact positioning. Additionally, the slide stop can be set to zero out the Dewalt back-and-forth movement, allowing the router to cut grooves purely by adjusting along the track without any back-and-forth movement.

Key Features:

• Compatibility: Fits the Dewalt DNP612 Trim Router Plunge Base and the standard Festool track saw track, ensuring smooth, stable positioning.
• Adjustable Cutting Width: Allows precise front-to-back adjustments to control groove width, reducing side-to-side play.
• Integrated Dust Extraction: Built-in dust extraction for a cleaner workspace. Designed to fit a Cen-Tec hose, with additional adapters for 58mm and 63.5mm hoses, making it versatile for various setups.
• Future Expandability: I designed the Track Base that slides down the Festool track as a separate part from the Tool Slide, allowing for potential future attachments. Based on the popularity of this model, I may create additional tool attachments for the Festool track using this same Track Base component.

Notes on Threaded Inserts:

The threaded inserts require a bit of extra press fit for a secure hold. Depending on your print, they may need a little more force to press into the hole. I used a wood clamp to carefully press the inserts into place, ensuring they were fully seated and flush with the surface.

Printing Specs:

To ensure optimal print quality and fit, please use the following recommended settings:

• Infill Type: Gyroid (provides strength and flexibility)
• Seam Position: For the Track Base and Slide Stop, set the Seam Position to Back. This keeps the seam away from grooves and key areas, preserving smooth movement and fit.
• Wall Loops: 8
• Top Shell Layers: 6
• Bottom Shell Layers: 4
• Infill Density: 20%
• Supports: Required on build plate only. I used "auto" with Tree Organic supports for optimal support and easy removal.

If using the provided 3MF files, these settings are already configured. However, if you’re using STL files in older software or on different printers, these settings are recommended to achieve the best results.

Additional Parts Required:

To complete this build, you'll need the following hardware:

• (10) M3 x 6 x 5mm thread inserts
  • Amazon Link
• (2) M3 x 8mm screws (for attaching the Track Base to the Tool Slide)
  • Amazon Link
• (4) M3 x 16mm screws (for securing the Slide Stop)
  • Amazon Link

Note on Filament and Tolerances:

This design features tight tolerances and was printed with Atomic PETG on a Bambu Labs X1E. After several prototypes, I achieved a perfect fit that allows the Dewalt router to glide back and forth smoothly while minimizing side-to-side play. I recommend Atomic PETG filament on a Bambu X1E printer for optimal results, though this design should work with other printers and filaments. Keep in mind that environmental factors and the way a printer applies filament may affect how smoothly the router glides.

Using other filaments, such as PLA, ASA, ABS, etc., may result in different shrinkage rates and will likely not provide the same optimal fit. I tested several materials for smooth operation and durability, and PETG proved to be the best choice for achieving the necessary size and tolerance for this design.

The Track Base and Tool Slide may feel a bit tight initially, but working them along the track several times can help them slide more freely. Some light sanding could be required on the Track Base or Tool Slide if needed, but in my case, sanding was not necessary. With my prints, moving the pieces back and forth on the track for a minute or two achieved a smooth, precise glide with tight tolerances.

Parts:

The design consists of three main parts:

1. Track Base
2. Slide Stop
3. Tool Slide with Dust Extraction

Two additional files are provided for hose adapters, allowing for modularity and adaptability with different setups.

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