Chris,
I had to make a deflector for my Hitachi too! I whipped it out on my wood lathe in short order and it works perfectly. I used a piece of 1/2" HDMW I had out in the shop. The area below the router is now null... completely void of energetic air... works a charm! If you haven't designed one as yet my pics might lay a foundation for yours. The only caution would be to have as large a gap between the deflector and the cast exhaust openings... BUT not so large a gap that the deflector interferes or prevents access for the locking shaft wrench. The thickness of the deflector plays a part in that too. Go thin... as thin as practical which will allow for the larger air gap. You don't want to impede a good flow of air as that will not allow sufficient cooling for the router.
The split dust shoe is a fabulous design...! One of those... "Why didn't I think of that...!" things...! Since we have the same router I await seeing your take on it...!!!
I KNOW what you mean about that smile...! It's such a tremendous sense of accomplishment when we get on the completion side of these builds!
HAPPY cutting...!
Steve
aka BOOMER52 >>> http://www.rcgroups.com/forums/member.php?u=159693