Parts list
| Material | Qty. |
| 2×4 foot 1/2 inch sheet of MDF | 4 |
| Repurposed IKEA desk purchased off Facebook Marketplace | 1 |
| 48×24 inch sheet of pegboard | 1 |
| 1/4 in x 1-1/4 in fender washer | 1 |
| 1/4 in -20 x 1in hex bolt | 1 |
| Phillips head cabinet hinge screws (10 per pack) | 1 |
| 2-1/2in O.D. 90° elbow dust connector | 2 |
| Bottle of wood glue | 1 |
| Dust control flex cuff with steel clamps 2 1/2 in | 4 |
| 4 in to 2-1/2 in reducer | 1 |
| 4 in dust control flex cuff with steel clamps | 1 |
| #6 x 1 in flat head Phillips head wood screws (100 per pack) | 1 |
| GE all purpose silicone caulk | 1 |
| 1/4 in – 20 T-nuts | 1 |
| 12 in table saw dust hood | 1 |
| Under cabinet light, 12 Inch plug in LED closet light | 1 |
| AC Infinity MULTIFAN S4, 140mm USB fan | 1 |
| Shop-vac | 1 |
| Dust Deputy dust separator | 1 |
| Recessed Power Grommet with 20W USB C Fast Charging, 2 inch Conference Recessed Outlet,Flush Mount for Desk,Office Tables,Furniture,6FT Cord, 45° Thin Flat Plug (Black, Grommet Outlet) | 1 |
The process
I snagged a used small desk from Facebook Marketplace for a steal! It’s got a metal frame and particleboard top, so I decided to give it a makeover. I painted the top red to match my style, and then I cut out a 11-inch square in the middle. I used a router with a rabbeting bit to add a 1/4-inch rabbet into the top. I put a 11 1/2-inch square piece of pegboard in the square hole, and I rounded the corners of the pegboard before placing it in the rabbet. Underneath the desk, I mounted a 12-inch table saw dust hood with 8 cabinet screws. I attached a reducer to switch from a 4-inch opening on the dust hood to 2 1/2-inch tubing. I used the hose from the shop-vac to connect the dust hood to the Dust Deputy dust separator. From the Dust Deputy dust separator, I ran another piece of tubing to my shop-vac. I used dust control flex cuffs with steel clamps at all the connections, and I also installed two 2 1/2-inch O.D. 90° elbow dust connectors to make the bends I needed in the run.
The box that sits on the desk is a 2×4 foot 1/2-inch sheet of MDF that I cut down to fit the desk. I painted the MDF a color called Cottage White to protect the surface and add some style to the box. I used a 4-inch hole saw to cut a hole at the top center of the box. I attached an AC Infinity MULTIFAN S4, 140mm USB fan to add extra down pressure to the air flow. I also installed a 12-inch plug-in LED closet light to the back of the box for lighting. I then drilled a hole for a 1/4-20 bolt to attach to a 1/4-20 tee nut and a phone mount so I can record a top-down view of my carving. Lastly, to power the box, I installed a recessed power grommet that has a 20W USB C port, a USB A, and a standard power outlet.
Outcome
Once the ShopVac is running, the suction is strong enough to pull most of the sawdust into the Dust Deputy dust separator. I still wear protective gear to keep the dust out of my lungs or eyes, but it’s much easier to manage with the downdraft table.
Reflections
If I had more money, I would have used 1/2-inch plywood instead of MDF, and I’m not sure if the fan really helps much.
Conclusion
Have you ever built your own downdraft table, and if so, what did you do differently?
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