Rectangular dust adapter: design & fit notes

This original design connects a straight rectangular tool outlet to a measured round hose cuff. A standard round reducer cannot fit a rectangular outlet. Set the outlet’s outside width, height, corner radius and engagement depth, then choose a socket or insert for your round cuff. It has no proprietary catches or locking features.

Measure with calipers at several points along the outlet. The rectangular cuff fits over the outlet: total clearance is added once to width and height, and half the clearance to corner radius. For the round connection, a socket’s inside diameter equals your cuff’s outside diameter plus clearance; an insert’s outside diameter equals your cuff’s inside diameter minus clearance. The displayed finished dimensions include these allowances.

Check corner shape as well as width and height. A paper tracing or radius gauge can help measure the corner radius. Choose cuff engagement lengths that fit the available straight sections. Tapers, threads, latches, recessed outlets and elbows are outside this design. Presets are starting measurements, not brand fit claims. Hoses, tools and clamps are separate.

The model has two straight cuffs and an open rectangular-to-round transition. The live model and downloaded STL use the same measured geometry. All inner and outer transition walls must move horizontally by no more than the transition height, limiting overhangs to 45° from vertical. Wall thickness is measured in horizontal sections; it is thinner perpendicular to a sloping wall.

Print upright with the rectangular cuff on the bed in PETG at 100% infill, using a brim. Valid configurations need no supports. The A1 check reserves an 11 mm total margin within the 256 mm bed, using a 245 mm envelope including height. Check the brim in your slicer. These are geometry checks; physical print, fit and airflow testing are pending.

The default adapter is $18 before shipping and tax. Changes in dimensions, bore, cuff lengths and wall thickness adjust the price using the volume and surface of the dimension-generated shell and the store’s PETG material and machine rates. The server recalculates the price at checkout. No collection performance or airtight seal is claimed. Support the hose independently; use only with dry woodworking dust, away from hot chips and sparks.

Read the original geometry source (TypeScript). Your measurements build locally in the browser, where you can download the matching STL.