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Connect a DeWalt random-orbit sander stepped port to a Festool D27 antistatic hose

How to join a DeWalt random-orbit sander stepped port to a Festool D27 antistatic hose, and what stops it leaking dust.

Reducer required

Not a direct fit. Joining the DeWalt random-orbit sander stepped port to a Festool D27 antistatic hose needs a 26 / 32 / 35 mm to 27 mm step reducer.

END A35 mmDeWalt random-orbit sander stepped port (1-3/8 in OD, 35 mm OD)

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

The two ends

End ADeWalt random-orbit sander stepped port (1-3/8 in OD, 35 mm OD)
End BFestool D27 antistatic hose (35 mm tip in OD, 7/8 in ID)
Fit typemale port into hose cuff
Reducer needed26 / 32 / 35 mm to 27 mm step reducer

Shop notes

Measured across the joint between the DeWalt random-orbit sander stepped port and the Festool D27 antistatic hose, the port (35 mm) is 12 mm larger than the hose (23 mm), so it will not seat. A 26 / 32 / 35 mm to 27 mm step reducer closes that 12 mm step so the two hold together instead of leaking at the gap.

A 12 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.