If you do a lot of sanding, you know how much of a mess it can create. A dedicated dust extractor makes a huge difference, but if you don’t have one, you can still get great dust collection with a shop vac and a 3D-printed adapter.
I own a Festool dust extractor and sander, which is an incredible setup for keeping dust under control. However, I recently had to send my Festool sander in for servicing, so I’ve been using my backup DeWalt sander. To keep my dust collection working, I purchased a 27mm adapter that’s compatible with my Festool dust extractor. If you’re interested, you can check out the adapter I bought here.
But what if you don’t own a high-end dust extractor? No worries! You can easily create your own dust collection system with a shop vac and a 3D-printed adapter—a much more affordable solution.
Step 1: Check Your Shop Vac Hose Size
Most standard shop vac hoses are 2.5 inches in diameter, but other common sizes include:
✔ 1.25 inches
✔ 1.5 inches
✔ 1.75 inches
✔ 2.0 inches
Some smaller, portable shop vacuums might use a different size, so always check your specific model before choosing an adapter.
Step 2: Get a 3D-Printed Adapter
If you have access to a 3D printer, you can design a custom adapter that connects your sander’s dust port to your shop vac hose. Here’s how:
1. Measure your sander’s dust port (outer diameter).
2. Measure your shop vac hose to ensure a snug fit.
3. Use a free 3D design tool like Fusion 360, Tinkercad, or FreeCAD to create a tapered adapter.
4. Slice and print your adapter using PETG or ABS filament for durability.
5. Test the fit and make adjustments if necessary.
If you don’t have a 3D printer, you can also purchase a ready-made adapter, like the one I linked above.
Step 3: Connect Everything
1. Attach the 3D-printed adapter (or purchased one) to your sander.
2. Connect your shop vac hose to the adapter.
3. If needed, secure the connection with a hose clamp, zip ties, or friction fit.
Step 4: Improve Your Setup
For a more flexible and easy-to-maneuver system:
✔ Use a lightweight, flexible hose instead of the stiff shop vac hose.
✔ Mount your shop vac on a rolling cart for better mobility.
✔ Add a vent hole to adjust suction if your sander feels restricted.
You can also purchase hoses if you prefer a professional solution. Here’s a link to my Festool dust extractor and some of my favorite inexpensive shop vacs: Check them out here.
Final Thoughts
If you already have a dust extractor, great! But if not, this DIY dust collection setup with a shop vac and a 3D-printed adapter is an affordable and effective way to keep dust under control. Whether you print your own adapter or buy one, it’s an easy upgrade that makes a big difference in your workspace.
Let me know if you try it—I’d love to hear how it works for you!
