Modifying Rockler 2 1/2" Blast Gate

Too much of the gate protrudes into the opening and inhibits air-flow on the 2 1/2" blast gate by Rockler.

  So I used a Dremel with a cut-off disc to saw off the stop.

I experimented by adding a stop making the gate less obtrusive but wasn't happy with the air seal when the gate was in the closed position.

Instead, I added an external block to stop the forward movement of the gate to make sure you can't pull it out entirely.  Also, note I've added heat shrink to the soldered leads on the micro-switch to avoid electrical shocks. (Don't ask my how I know about this.)

Note that Woodcraft sells a version of this plastic gate with a stepped sliding piece that minimizes the air-blockage problem.  Here is a photo:




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