TLDR: We designed our ports to be quick-connect ports. Which allows you to effortlessly move the vacuum hose between tools. We sacrificed dual functionality for ease of use. Which is different from Festools' approach.
Mort,
That is a great and interesting question. Most Festool dust ports are "dual" size ports. A 27mm / 36mm dust port comes standard on their track saws, routers, and Kapex. To accomplish this dual-port they seem to have had to compromise the ease of use for both ports. They have decreased the size of the ID of the 27mm portion of the port and increased the OD of the 36mm portion of the port.
The 27mm twist-lock uses the interior of the 27mm /36mm dust port. The OD of the 27mm hose is 36.2mm, while the ID of the port it goes into is 36mm. The port is actually smaller than the vacuum hose. This is why it requires some force to push in. The 36mm twist-lock goes around the outside of the 27mm/36mm port. The ID of the 36mm hoses ID is 36mm, but the OD of the port is 39.5mm + the thickness of their twist-lock tabs. The port being larger than the hose is what requires so many forces to attach the hose.
I designed our replacement ports to be "quick connect". I increased the size of the ID on the 27mm port so that the 27mm twist-lock glides in and twists securely with absolutely minimal force. Along with decreasing the OD on the 36mm port so that the 36mm hose quickly connects as well. We generally find that people have one size of dust extractor hose and they would rather have ease of use 95% of the time, than frustration 100% of the time.
What do you guys think? Right decision or wrong?
Thanks,
-Andy Wilkerson
Black Raptor Tools.