I wanted to give a quick update about what I am working on. Last weekend, I hit up the aluminum store and grabbed some 3/8" thick drops of 6061 plate to play with. I still have to get some tooling for aluminum before I start letting the chips fly!
Anyway, here is what I am currently thinking for the dust shoe... I'll post the geometry if it works out.
The shoe is made up of three layers, two screw together and the last layer that holds the brush is attached with magnets for easy access to the collet. The middle layer redirects the router air-flow out the front of the shoe.
One of the things I learned from the dust shoe for my MDF machine is that if the brush has a straight side this can sort of pole-vault over geometry. If all sides of the brush are curved, this sort of eases the brush over cuts. This shape also allows for rotation of the brush to the side for the most efficient collection while surfacing. I also bought an LED light to play with some task lighting ideas.
I hope I can get around to cutting it out next week!
Grünblau Design Studio