Genmitsu CNC Dust Shoe Adapter 52mm to 55mm

I've been using the inexpensive but rather nice Genmitsu magnetic dust shoe on my DIY CNC router with a 500w 52mm spindle. I recently overhauled and built a new improved (is it new or improved, can't really be both) and due to the electronics enclosure the old spindle controller was putting off way to much EMI for my liking. I decided to upgrade but was not ready for the whole VFD motor setup just yet so I went with a 500w brushless. It's way quieter and fits the gantry design I'd already designed and cut out. The problem turns out to be though that this spindle is 55mm instead of 52mm and that makes it a VERY odd man out as there are essentially no real 3rd party support for it like dust shoes. Including the very manufacturer I bought it from. I went a little while with no shoe at all and after surfacing the MDF spoilboard and cutting out a bunch of bench dog pockets. Well EVERY conceivable inch of my garage was covered in a fine dust. I was using a large dust collector too as well as an air scrubber aka the hamster thunderdome (see my other designs). So I knew I needed something at this point.

I didn't want to design my own from scratch, although that might just happen from what I see. Instead I already had this 52mm shoe so I set out one afternoon and redesigned the part I needed to fit 55mm and mate with the Genmitsu shoe. It fits and works but it is a snug fit. This doesn't surprise me since I don't have a 3D scanner or anything like that and just used my calipers and repetition to make it work. I designed it such that you can use the existing screws and magnets in the original top part in this new one but you could very easily edit the step files to make it use press in. I also made the hose insert to fit my elbow and it has a 32mm interior diameter. They are 2 separate pieces that snap together quite well but a dab of CA glue can come in handy. I made them separate so that different hose sizes could be adapted and so that no supports would be needed when printing.

I printed mine in PETG because the spindle can get warm and PLA might be unhappy over time.