Pnut's compressor box build

[pnut]

I got a new 60 gal Husky for Xmas. It was quieter than my oil-less by ALOT, but I still wanted it to be virtually silent, so I set about building a box.

Materials are 1/2" OSB, 2x4's, and leftover deck screws. I did quite a bit of planning the basic shape, air plumbing, and electrical.

First I made the sides: I laid out the 2x4's on the floor, laying the OSB on top, first screwing the OSB to the 2x4's, then using longer screws to attach the 2x4's to each other at the joints.

I then skinned the back with the OSB, adding in 2x4's along each edge, finally skinning the top with the OSB. I then made the door just like the sides, and eventually attached with some hinges.

Air circulation:
Intake from the outside, and exhaust using a Radio shack fan (max CFM one they had). The air intake and exhaust panels I made using some 2x2. I glued on some door seal felt using hot glue to keep the noise in, but still flow air.

Feet and drain:
Drain is extended but still inside the box. Not sure if I may change this. The feet I got used from my company's leftover used industrial supply bits they let us buy at wholesale. Rubber softer than hockey pucks.

Electrical:
Fan is wired up to a switch so I can turn it on and off, wired to a plug at the wall. Compressor is not only plugged into an outlet in the box, but I also added a double pole switch wired to a plug into the wall. I had to add a 220 circuit which was not terribly hard.

Plumbing:
Shutoff at the tank, flex line through the box to the Norgren Regulator / Filter. Then flex line to the copper line which goes up into the ceiling, and eventually into the ceiling mounted reel. I did add a "t" with shutoff. The plumbing in the attic is slanted just a bit so the condensation will flow down to the "T" for draining.

Finishing:
- I used old tubes of caulk to seal every joint.
- I painted the whole thing with high gloss paint and vinyl stripes to match the walls. First two coats soaked up ALOT of paint.
- I attached R13 insulation with a staple gun. Still not sure how well it will hold up. One concern I do have is tiny glass fibers getting blown out of the box from the fan. Maybe it's nothing.

How quiet is it?
Very quiet, suprisingly so. It is about the same as our new dishwasher. You can have a very quiet conversation standing right in front of the box.

What would I do differently, what don't I like?
- Not sure if the fan is enough to keep the compressor cool.
- I wish I would have measured much more carefully as it's not perfectly square.
- Wish I would have done it years ago.

Here it is in place in my garage (I'll make another post about the whole garage renovation I did this winter in a separate post):

 

[Keith_MN]

Looks good, but I too am worried about the temperature in that box. That fan does not look like it will move enough air to keep it cool.

I would recommend putting a thermometer inside the box near the top and running it for a while to see what the temperature rise is over ambient. This delta in temperature is what you want to watch. If for example, the garage is 65F and the cabinet is 90F, that might be OK for now. However, keep in mind when summer comes around and the garage is 90F, that cabinet will probably be 115F. These temperatures will probably start to reduce the life of the compressor.

-Keith

 

[porschedude996TT]

How does it work? I was thinking that the wall insulation that is made to reduce noise would work better than the pink fiberglass.

 

[dfndr]

Thanks for the very informative post. I'm looking to do the same but the compressor and box may be put outside, against the wall of the garage. Problem is that the temp gets to 110 plus during the summer, with virtually no humidity and the box will be in the direct afternoon sun. What kind of air flow do I need in that case? Your box is nice indeed. I would just add a sloped roof if I put it outside.

 

[Stuart in MN]

The labyrinths on the intake and exhaust vents are a nice touch.

 

[Tom2]

That's a pretty nice setup.. I agree that the fans look way too small. May be better off simply using regular window fans from Wal-mart, etc.. The rectangular ones that are several inches high by about 20inches wide.
About the size of the intake and exhaust ports.

Of course, if the compressor started running frequently (like, if you were sandblasting or painting a car) you could just leave the door open..


You may want to loosen the mounting bolts on the rubber. The vibration will dampen better. The owners manual for my Husky suggested that.. I'm not one to talk though. I just got mine last week, and I'm using it on the pallet for time being.. Looks like good soft rubber though.

Overall looks great. Looks like a fridge!


My 80 Gallon Husky/CH is insanely loud. I would love to build a cabinet as well. Right now the garage door track would kinda be in the way of any enclosure, so would need to move the compressor. Ideally on an exterior wall with a couple of vents to flow fresh air in and out.

 

[crewchief888]

i was wondering if anyone has tried using acoustical ceiling tile for a noise dampener?
like the stuff they use for suspended ceilings........

just wondered

 

[the spyder]

Have you considered covering the insulation with a 6mm plastic wrap? I would be very concerned the compressor will **** in fibers and they will act as an abrasive. You should look for a small squirl cage fan off a range, exhaust vent, ect. They will move more air, last longer, and run pretty quiet. I have had several Rat shack fans fail.

 

[pnut]

Thanks for the comments. About the fan / heat....
Yes I have considered using a larger fan, and still may. Although you would be surprised how much air that fan moves. A larger fan would mean I would have to increase the intake and exhaust opening size, which means thicker/new labyrinths, and the box then farther away from the wall.

I would not want to just have an open hole without the labyrinths because then the noise would just shoot out the holes.

So my plan is to wait and see. I figure I will know if there is a problem if the thermal shutoff kicks in. I will say after a full 0-150PSI cycle (4-5 mins constant), the whole thing did get reasonably warm, but that is much longer than it would normally run cycling, and I would keep the fan on constant even when it is not running. I would for sure need more air circulation if I was using a die grinder excessively or sandblasting, however most of my needs are impact wrench, tire filling, air blowing (purge water hose), and 3/8 air drive wrench, so we will see.


A poster asked about plastic on the insulation, and another about other insulation fibers in the air. Yes for sure I am thinking about covering or changing the insulation. I think the plastic would take away from some of the sound insulation, though. I would switch to the eggcrate foam if I come across some. That would eliminate the fears of glass fibers in the pump, or being blown into the garage air.

 

[rieferman]

landscape fabric might be a good option for covering the insulation. Cheap, easy to work with, and it would still allow for the sound to penetrate and dissipate in the material.

I think a cheap thermometer (like an Extech with a remote sensor) would be worth the investment for peace of mind. I know for a low cost, you can set an alarm point on some of them even.

edit: something like this.. If I remember correctly these are under $20. http://extech.com/instruments/product.asp?catid=67&prodid=392

really nice job on this!

 

[mooman]

Why not run the hose downhill instead of uphill? Wouldn't this pose a problem for air in the lines?

 

[pnut]

Why not run the hose downhill instead of uphill? Wouldn't this pose a problem for air in the lines?

I'm not sure I understand what you mean? Can you clarify.

If you mean the copper line inside the ceiling, it is slightly angled from the hose reel end, to the wall end, so that the condensation drains down the copper pipe in the wall, and I can drain any off from the "T" mounted on the wall.

 

[Falcon67]

Speaking of hose - I see 1) water trapped in the loop just off the compressor and 2) if it's not 1/2" inside, it'll likely be a restriction at some point. 3/4" hydro hose from Tractor Supply straight up and out of the box would be 100x better.

 

[Tom2]

I'd definitely switch to egg crates. Cheap, and peace of mind.

I've got some left over carpet and padding..That's what I'll use when/if I build one.

 

[Rosco]

Frickin genious..........great thread. Now I have more work to do.

I have a craftsman professional oiless compressor that is very, very loud. Is this new one you have that much better?

 

[pnut]

Frickin genious..........great thread. Now I have more work to do.

I have a craftsman professional oiless compressor that is very, very loud. Is this new one you have that much better?

Yes, I sold my 25 gallon "5hp" upright Craftsman oil-less (10 yrs old and in great shape) for $130 cash. .

MUCH quieter. Don't expect silence though, it does make noise, but no where near like the oil-less.

 

[GreyOwl]

My only question is whether you have enough supply air on the intake side to handle both the needs of the compressor and the exhaust fan. If it isn't you may be pulling air in past the fan as it is trying to push it out. Another source of the eggcrate foam is a mattress topper but not sure of the cost.

Charles

 

[A29]

Put mine outside in a box with sloped lid with shingles. Added an old return air cover for extra ventalitation. Put a switch inside the shop and ya can hear it running. Most of a compressors noise is the air intake and I had already made a muffler for it.

 

[tonydanzah]

i would be afraid that fan is to small,

 

[Falcon67]

> Most of a compressors noise is the air intake and I had already made a muffler for it.

YMMV - I ran the air intake on my 3.5 HP./60 G Campbell unit up into the attic. Topped with a muffer installed in a 6" air cleaner. Made zero change in the dB level coming from the compressor. BUT - you can hear the compressor much better on the side of the shop where the gable vent it located. I hear Nelson sayin "Ha, ha!"

 

[s_ontario]

That poor compressor your going to melt it christ mine is in a 14'x14' cement block building and i don't even need heat in that room when i'm pushing the compressor hard
have 911 on speed dial man

 

[pnut]

That poor compressor your going to melt it christ mine is in a 14'x14' cement block building and i don't even need heat in that room when i'm pushing the compressor hard
have 911 on speed dial man

I'm going to have to respectfully disagree. I will be keeping an eye on the temperature, and if I need to up the intake size, and larger fan, then I will.

 

[Tom2]

I wonder how loud it would be with the top removed? Say, with the sides extended 5 inches higher than the top of the compressor. Then, any heat would easily escape. No worry about overheating - and would probably still deaden the noise quite a bit.

Just curious.. May try that with mine.

 

[s_ontario]

I wonder how loud it would be with the top removed? Say, with the sides extended 5 inches higher than the top of the compressor. Then, any heat would easily escape. No worry about overheating - and would probably still deaden the noise quite a bit.

Just curious.. May try that with mine.

what would help is forget the fan and have the box extend right up through ceiling and above trusses so the heat could get into attic space

the pump gives off alot of heat

 

[Tom2]

If that is an option, then absolutely.

My house though, the garage is directly below the living room.

 

[pnut]

what would help is forget the fan and have the box extend right up through ceiling and above trusses so the heat could get into attic space

the pump gives off alot of heat

At that point, you may as well just mount it in the attic, with no need for a box. I decided against that due to the difficulty of getting it up there, plus lack of access to it.

 

[LWW]

I built a similar shed for my 60 gallon IR out of 2x4's firring strips and some 1/4" OSB with R19 insulation, but I had batten on mine to keep the fibers down. Mine has a sloped roof with left over shingles from my new roof. It has a 1" gap between the back wall and the tall side of the roof to exhaust heat. I still need to make an intake muffler, but since it's outside, it's mostly for the benefit of the neighbors.

 

[manansal]

nice job!

i hope to build a box around mine soon. it's right next to my desk!

 

[pnut]

I built a similar shed for my 60 gallon IR out of 2x4's firring strips and some 1/4" OSB with R19 insulation, but I had batten on mine to keep the fibers down. Mine has a sloped roof with left over shingles from my new roof. It has a 1" gap between the back wall and the tall side of the roof to exhaust heat. I still need to make an intake muffler, but since it's outside, it's mostly for the benefit of the neighbors.

Do you have any pictures? I would love to see it.