I think part of the reason it does not come with longer bristles is because you do not want the bristles being able to make contact with the cutter and get wrapped around it.
Good point, I can see it now with the small diameter foot print that longer could do that. Just kind of disappointed that the sweep with the small bristles leaves so much of a gap between the bit and the surface. Love the design, I am still using it but have to vacuum up after each run. Wonder if Carbide run into this issue with longer bristles causing issues.
Cool, here my original dust boot, I really like it because the bristles are really soft plus long. The only thing I didn’t like is pressing the button on the dewalt router. The left side of the boot in the plastic has a notch which partly covers the locking button the dewalt. Easy to get on and easy to get off with magnets.
One things I did notice, about the bristles. I now have a HDZ screw Z drives, but when I didn’t I had issues on other dust boots. The problem was that I seen a lot was the bristles if they where too stiff, it would make the Z jump sometime. Now that was with the BELT version of the Z on the Shapeoko. I kicked that dust boot out and told it to take a hike.
My 2 cents, make the bristles really soft, and make the access to the lock on the router easy to get too.
So far they seem to be holding up. I used double layers of vinyl and made the flaps 3/4 of an inch wide. This coupled with my Meile vacuum which allows me to adjust the amount of suction seems to be doing the trick.
I did however have to strengthen the router clamp. If you look closely in my pictures the clamp broke where the nut is.
One thing I really like about this design is that the clamp can be rotated around the hose plate so you can have the vacuum hose on the right side and still have the clamping screw towards the front.