Connect a DeWalt random-orbit sander stepped port to a 2-1/2 in shop-vac hose
How to join a DeWalt random-orbit sander stepped port to a 2-1/2 in shop-vac hose, and what stops it leaking dust.
Not a direct fit. Joining the DeWalt random-orbit sander stepped port to a 2-1/2 in shop-vac hose needs a 26 / 32 / 35 mm to 2-1/2 in step reducer.
Rings drawn to scale from the measured diameters in the table below.
The two ends
| End A | DeWalt random-orbit sander stepped port (1-3/8 in OD, 35 mm OD) |
|---|---|
| End B | 2-1/2 in shop-vac hose (2-1/4 in OD, 2-1/4 in ID) |
| Fit type | male port into hose cuff |
| Reducer needed | 26 / 32 / 35 mm to 2-1/2 in step reducer |
Shop notes
Measured across the joint between the DeWalt random-orbit sander stepped port and the 2-1/2 in shop-vac hose, the hose (57 mm) is 22 mm larger than the port (35 mm), so the port rattles inside without gripping. A 26 / 32 / 35 mm to 2-1/2 in step reducer closes that 22 mm step so the two hold together instead of leaking at the gap.
A 22 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.
Related connections
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