I recently upgraded my 4 XXL to an 80mm spindle ( common one available on Amazon), which if I can say is a complete game changer. Very quiet, rpm control and power to spare. If you are considering it I highly recommend the upgrade.
In any case I was looking for an 80mm dust boot and potentially one that was Z-Axis independant. After much research and reading on the forums I couldn’t decide which route to take with the commercially available ones or a diy version and I was growing tired of the mess running without dust collection.
I noticed that on my spindle there is a collar below the main body and it looked suprising close to the diameter of the old 65mm router that I was using. I measured the collar and it measured 59.6mm. I considered fabricating some sort of spacer so I could slip the existing Sweepy onto the collar but after several suboptimal solutions I went looking for something better.
I stumbled upon a clear acrylic tube on amazon ( $17 CAD ) that had an interior diameter of 61mm and an outside diameter of 65mm.
I recieved the tube and cut a length and when placing it on the collar it was perhaps 1mm larger, I cut four slots in the end of the tube and with a pipe clamp I was able to firmly attach it to the collar.
I then slipped the 65mm Sweepy over the tube with a snug fit.
All I can say is that it worked out perfectly. I doesn’t have a full range of adjustment, but I can get 3 or 4 different lengths of adapters out of the tube that I ordered, and I can re-use the dust boot I already have. Which gives me more time to find a more permanent solution.
I posted this in case anyone else is in the same situation and needs an inexpensive solution for a dust boot after upgrading from the 65mm carbide router to an 80mm spindle.
Hope this helps.
Claudio