How to Use the DeWalt DW735 Thickness Planer

The DeWalt DW735 is a portable benchtop thickness planer featuring a powerful 15-amp motor with a built-in fan-assisted chip ejection system. This guide will help Reforge Charleston members safely and effectively operate this versatile tool for dimensioning lumber and achieving smooth, precise finishes on wood surfaces.

Safety First

⚠️ CRITICAL: THIS PLANER MUST BE USED WITH THE DUST COLLECTOR ATTACHED AT ALL TIMES. Never operate the DW735 without proper dust collection connected to the exhaust port.

Always wear safety glasses when operating the planer
Wear a dust mask or respirator—planers create significant airborne dust and chips
Never reach into the planer while it is running or powered on
Keep hands, ties, and loose clothing away from all moving parts
Never plane material shorter than 12 inches (304.8 mm)
Always feed material with the grain whenever possible to prevent tear-out
Never allow children to operate or come into contact with this tool without supervision
Use extreme caution when planing narrow stock; group thin pieces together when possible
Never make adjustments or change knives while the planer is plugged in
Unplug the tool before clearing jams or making any repairs
Allow the planer to come to a complete stop before removing material
Do not operate when tired, under the influence of drugs, alcohol, or medication

Equipment Overview

The DW735 is a professional-grade portable planer designed for woodworking shops and makerspaces. It features a three-knife cutter head for clean, smooth finishes and a two-speed gearbox allowing you to optimize between rough material removal and fine finishing work.

Key Specifications:

Motor: 15-Amp, 120V AC
Cutter Head: Three-knife reversible design
Maximum Cutting Depth: 1/8 inch (3.2 mm) per pass
Maximum Board Width: 13 inches (330 mm)
Planing Capacity: 6 inches (152 mm) maximum width at full depth
Speed Options: 96 CPI (Cuts Per Inch) or 179 CPI
Feed Rate: 14-20 feet per minute (depending on speed setting)
Dust Port: 4-inch (102 mm) diameter for collection system attachment
Weight: Approximately 155 lbs (70 kg)
Built-In Fan: Assists chip ejection but requires dust collection system

Understanding the Built-In Chip Ejection System

IMPORTANT: The DW735 has a built-in chip blower, but this is NOT a substitute for dust collection. The blower ejects chips with force but creates significant back-pressure if not properly managed with a dust collection system.

The fan-assisted chip ejection system is designed to work in conjunction with an independent dust collection system. The built-in blower provides the initial force to move chips through the exhaust port, but a separate dust collection system must capture them. Note: Most shop vacuums alone cannot keep up with the volume of chips from the DW735—see the Dust Collection section below for proper setup.

Getting Started: Pre-Operation Checklist

Before operating the DW735, complete this important safety checklist:

Verify the dust collection system is connected and operational before starting
Check that the planer is unplugged from the power source
Inspect the cutting knives for damage, dullness, or chips
Verify all guards and safety covers are in place and secure
Ensure the planer table is clean and free of debris, oil, and pitch
Check that all bolts mounting the planer to the bench are tight
Verify the depth adjustment scale is readable and accurate
Confirm the feed table is flat and not warped
Clear the work area of obstacles and bystanders
Put on safety glasses and a dust mask before operation

Dust Collection Setup

The DW735 MUST be used with a dust collection system attached. This is not optional for safe operation at Reforge Charleston.

Important Note from DeWalt: It is NOT recommended to connect a standard shop vac directly to the DW735. The capacity of most shop vacuums cannot support the volume of chips ejected by the planer, and the vacuum hose may clog, stopping chip flow and creating back-pressure that damages the planer.

Recommended Dust Collection Solutions:

Cyclone Dust Collector: A cyclone separator on top of a collection drum is ideal. The cyclone separates chips and dust efficiently, and the large collection capacity handles the planer’s output without clogging. Use a 30-55 gallon drum minimum.
Commercial Dust Collection System: Connect to a dedicated dust collection system (1-2 HP minimum recommended). Ensure the system is turned on before starting the planer to establish proper suction.
Chip Collection Bag: DeWalt offers a chip collection bag (DW7350) specifically designed for the DW735. This is a budget-friendly option for light-duty work. Bags should be emptied frequently as they fill quickly.
External Exhaust Setup: If your shop allows, direct the exhaust hose out a window or door to an external collection container—this eliminates back-pressure issues.

Dust Collection Best Practices:

Always start the dust collection system BEFORE turning on the planer
Use a 4-inch diameter hose (matching the exhaust port size) for proper airflow
Keep hose runs as short as possible; longer runs reduce collection efficiency
Inspect the hose and collection system regularly for blockages
Empty collection bags or drums frequently—a full container creates back-pressure
Never block or restrict the exhaust port during operation
Allow 10-15 minutes of dust collection after planing stops to clear residual chips

Setup and Installation

Bench Mounting

The DW735 should be mounted on a sturdy, level workbench that can support approximately 155 lbs plus the weight of material being planed. Secure the planer using the mounting holes in the four corners with bolts (recommended for stability). Ensure adequate clearance on the outfeed side to prevent material binding after it exits the planer.

Attaching the Depth Adjustment Crank Handle

Insert the depth adjustment crank handle into the socket on the side of the planer. The handle should fit securely. Use this crank to adjust the cutting depth—rotate clockwise to increase depth (lower the table) or counterclockwise to decrease depth (raise the table). Maximum depth per pass is 1/8 inch.

Setting Up Dust Ejection

Attach the 4-inch diameter dust collection hose to the dust ejection port on the rear of the planer. Ensure a tight, secure connection to prevent air leaks. Connect the opposite end to your dust collection system. Always verify that dust collection is operational before powering on the planer.

Operating the DW735

Step 1: Prepare Your Material

Select lumber that is at least 12 inches long and reasonably flat. For cupped or twisted boards, use a planer sled or flatten one surface beforehand. Ensure the workpiece is not nailed, screwed, or contains any metal objects that could damage the knives. Material should be at room temperature and acclimated to your shop’s humidity.

Step 2: Set the Cutting Depth

Use the depth adjustment crank on the side of the planer to set your desired cutting depth. The depth adjustment scale shows the finished thickness you’ll achieve. Start conservatively—1/16 inch to 1/8 inch per pass is typical. Lighter passes produce better finish quality and reduce motor strain.

Step 3: Select Speed Setting

The DW735 has two speed options controlled by a switch on the front. Speed “2” (179 CPI) is faster for rough dimensioning work. Speed “1” (96 CPI) is slower and produces the finest finish, ideal for final passes. You can switch speeds while the planer is running without stopping it.

Step 4: Start Dust Collection

TURN ON YOUR DUST COLLECTION SYSTEM FIRST, before starting the planer. This is critical to prevent back-pressure and ensure safe operation. Wait 5-10 seconds for the dust system to reach full suction.

Step 5: Power On and Feed Material

Lift the ON/OFF switch on the front of the planer upward—the planer locks on automatically. Wait for the cutter head to reach full speed (about 1-2 seconds). Place your material on the infeed table and gently feed it into the planer. The feed rollers will grip and pull the material through automatically. Do not force the material—let the planer feed it at its own pace.

Step 6: Monitor the Pass

Watch the material pass through the planer. Do not reach into the planer or put your hands anywhere near the feed area. Listen for normal operation—any unusual sounds may indicate a problem. The planer should not stall or slow significantly during normal operation.

Step 7: Remove the Workpiece

After the material exits the outfeed side, let it clear completely. Do not remove it until it has completely passed through the planer. Keep your hands away from the cutter head area.

Step 8: Power Off and Clean

Press the ON/OFF switch downward to turn off the planer. Let the dust collection system run for 10-15 minutes after you stop planing to clear the remaining chips and dust. Once the planer has stopped, wipe down the exterior and clear any accumulated chips from the surfaces.

Planing Tips for Best Results

Feed Direction

Always feed wood with the grain—this means feeding so the grain rises as the material moves through the planer. This produces a cleaner cut with less tear-out. If you’re uncertain of grain direction, feed from the end that feels smoother to the touch when run against your hand.

Multiple Passes for Twisted or Cupped Wood

For twisted wood, flip the board back and forth between passes. This gradually flattens the board while preventing snipe. For cupped wood, plane the concave (cupped) side first to flatten it, then flip and plane the other side. Use a planer sled or featherboards to hold cupped or twisted material flat during planing.

Taking Light Passes

Taking multiple light passes produces superior results compared to fewer aggressive passes. This reduces strain on the motor, minimizes tear-out, and extends the life of your knives. A good approach is to start with 1/16-inch passes and increase to 1/8-inch as you gain experience and confidence.

Using the Turret Stop

The turret stop allows you to preset consistent depths for multiple boards. Set it to your desired depth and the planer will automatically stop the feed table at that thickness. Pre-set depths are available at 1/8″, 1/4″, 1/2″, 3/4″, 1″, and 1-1/4″.

Finishing Passes

On the final pass, use Speed “1” (96 CPI) for the smoothest possible finish. This slower feed rate allows the knives to make cleaner cuts. A final finishing pass of only 1/32 inch can significantly improve surface quality.

Painted or Treated Wood

It is generally acceptable to plane most painted wood, though blades may dull faster. However, do NOT plane wood with lead-based or cementitious (waterproofing) paint due to health and environmental hazards. If in doubt, ask a staff member.

Knife Replacement and Maintenance

Recognizing Dull Knives

Dull knives produce tear-out, rough surfaces, and increased noise. If your planed surface looks rough or fuzzy or if the planer is struggling to feed material, the knives likely need replacement. The DW735 knives are reversible—one reversal extends blade life before replacement is necessary.

Changing the Planer Knives

Unplug the planer from the electrical outlet
Remove the dust hood to access the cutter head
Locate and engage the blade lock lever to lock the cutter head in place
Use the provided wrench to remove the lock nuts holding the knives
Carefully remove the old knife blades, noting their orientation
If reversing blades, flip them and reinstall in the same orientation
If replacing, align the new knives with the marks on the cutter head
Re-tighten the lock nuts securely—proper blade seating is critical
Verify the knives are flush with the table surface
Reassemble the dust hood and secure all fasteners
Verify the top cover is properly seated before plugging in the planer

Cleaning the Planer

After each use, wipe down the planer exterior with a damp cloth
Clear wood shavings and chips from the feed table and around the cutter head
Use compressed air to blow dust from motor vents and air intake areas
Periodically treat the table with paste wax (NOT automotive wax) to maintain smoothness
Regularly clean and remove debris from the chip ejection fan housing
Never use solvents or harsh chemicals on plastic parts—use water and mild soap only

Troubleshooting Guide

Planer Won’t Start

Verify the planer is plugged in and the outlet has power
Check the circuit breaker hasn’t tripped (planer has an 18-amp breaker)
Try a different outlet to rule out circuit issues
Verify the ON/OFF switch is functioning properly
If still not working, unplug and contact a qualified technician

Circuit Breaker Trips During Operation

Check for dull knives and replace or reverse as needed
Reduce the depth of cut (try 1/16 inch instead of 1/8 inch)
Switch to Speed “1” (slower, less demanding)
Reduce the feed rate to 14 ft/min
Unplug other devices sharing the circuit with the planer
If breaker continues to trip, the motor may need professional service

Rough or Torn Surface Quality

Check knives for dullness and replace or reverse if necessary
Verify you’re feeding with the grain (lift end of board that feels rougher)
Take lighter passes (reduce depth to 1/16 inch)
Use Speed “1” for the final pass
Ensure the planer table is clean and free of debris or pitch
Check that the material is flat and not cupped or twisted

Material Not Feeding Through Properly

Verify dust collection system is connected and running—blockages create feed problems
Check for jams or debris in the feed area
Unplug the planer and clear any blockages with your hands
Ensure the depth adjustment crank is locked in position
For narrow material, group pieces together and plane as one wider board
Check feed roller alignment and adjust if necessary

Excessive Dust Escaping or Collection System Clogging

VERIFY THE DUST COLLECTION SYSTEM IS CONNECTED AND RUNNING
Check the hose for kinks, blockages, or disconnections
Empty the collection bag or drum if full
Inspect for hose clogs and clear as needed
Verify hose diameter matches the exhaust port (4 inches)
Consider upgrading to a cyclone separator if using a standard collection bag
Never operate without dust collection connected

Regular Maintenance Schedule

Daily/Per-Use: Clean exterior and infeed/outfeed tables; clear accumulated chips

Weekly: Inspect knives for dullness; lubricate feed rollers with light machine oil; check power cord for damage

Monthly: Check belt tension and look for wear; inspect all bolts and fasteners for tightness; clean dust collection system

Quarterly: Reverse or replace planer knives; treat table with paste wax; inspect motor vents and clean air pathways

Annually: Consider professional inspection and service; verify calibration of depth adjustment scale

Reference Materials

Official Documentation:

YouTube Tutorial Videos:

DeWalt DW735 Beginner Tutorials – Basic operation and setup
Planer Basics and Fundamentals – General planing techniques
Planer Knife Replacement and Maintenance – Blade care and replacement
Feeding With the Grain to Prevent Tear-Out – Achieving smooth finishes
Dust Collection Setup for Planers – Proper collection system installation

Related Topics:

Dust collection systems and safety
Wood preparation and grain direction
Knife sharpening and maintenance
Working with figured and difficult woods
Personal protective equipment (PPE) for woodworking
Jointer operation (complementary tool for surfacing boards)

Questions or Need Help?

Always ensure the dust collection system is connected and operational before starting the planer. If you have questions about operating the DW735 at Reforge Charleston, please reach out to a staff member or certified instructor. Safety is our priority, and we’re here to help you achieve excellent results!

Last Updated: November 2025

How to Use the DeWalt DW735 Thickness Planer