PortMatch
CONNECTION

Connect a DeWalt miter saw dust elbow (1-1/2 in outer) to a Festool D27 antistatic hose

How to join a DeWalt miter saw dust elbow (1-1/2 in outer) to a Festool D27 antistatic hose, and what stops it leaking dust.

Reducer required

Not a direct fit. Joining the DeWalt miter saw dust elbow (1-1/2 in outer) to a Festool D27 antistatic hose needs a 1-1/2 in to 27 mm step reducer.

END A38 mmDeWalt miter saw dust elbow (1-1/2 in outer) (1-1/2 in OD, 38 mm OD)
END B35 mmFestool D27 antistatic hose (35 mm tip in OD, 7/8 in ID)

Rings drawn to scale from the measured diameters in the table below.

The two ends

End ADeWalt miter saw dust elbow (1-1/2 in outer) (1-1/2 in OD, 38 mm OD)
End BFestool D27 antistatic hose (35 mm tip in OD, 7/8 in ID)
Fit typemale port into hose cuff
Reducer needed1-1/2 in to 27 mm step reducer

Shop notes

Measured across the joint between the DeWalt miter saw dust elbow (1-1/2 in outer) and the Festool D27 antistatic hose, the port (38 mm) is 15 mm larger than the hose (23 mm), so it will not seat. A 1-1/2 in to 27 mm step reducer closes that 15 mm step so the two hold together instead of leaking at the gap.

A 15 mm mismatch feels close enough to force, and it will hold for a minute before it works loose under airflow. Fit the step ring rather than trusting friction on a gap this size.