Homemade or low buck dust collection systems?

red73mustang · Jan 1, 2013

Wow I just finished going through 40 pages of the Workbench thread and I was wondering if anyone had some tips on how to build a low coast dust collection system that is effective and practical. I have a couple of old 5 gallon shop vacs that don't get much use that I could use, but I'd be interested in any other ideas.

Regards, Chet

bullnerd · Jan 1, 2013

I built one about 15yrs ago.A guy I was working with bought a profesional one and let me take the cover off and measure the impellar blades.I copied it and its been running ever since.I'll try to get some pics.Only thing I bought was a good dust bag.

bob15 · Jan 1, 2013

I bought this a couple weeks ago. When attached to my shop vac it did a real good job of "catching" the sawdust and woods-chips and dropping them into the steel barrel that came with it. For $200, I think it was well worth it.

http://www.oneida-air.com/category.asp?Id={CC6B6F2A-E3D7-4F18-A53C-B5C357DFE131}

bob

wrench409 · Jan 1, 2013

There's plenty of DIY videos on youtube regarding these and some look promising.

I have and old Dayton Shop Vac (late 70's ish). It's just a short metal 5 gal barrel on wheels. I am going to replace the 5 gallon barrel with a 30 gallon barrel, build in a cyclone/vortec system and plumb the garage with 3 - 4 pickup spots for connecting different woodworking tools. Then place it next to my compressor out in the shed - so I can listen to tunes in the garage.

Tim The Tool Man · Jan 1, 2013

I ran 6 and 4 inch ducting throughout my shop to all my tools. I picked up a 1.5hp Penn State dust collector off craigslist and built a Thien dust separator out of a 55 gal. drum. I spent under $350 all said and done. I posted info on the separator here: http://www.garagejournal.com/forum/showthread.php?t=170345

Hause · Jan 1, 2013

interesting reading on making your own here, he has plans too: http://billpentz.com/woodworking/cyclone/index.cfm

PECVD2 · Jan 1, 2013

I picked up this Chicom 3/4hp blower for $20 and a USA trash can then used an old CM blower/Vac bag as the separator in the can. I found the 5micron bag and some blast gates on clearance at woodworker supply. The 6" hose and some couplings were purchased off my brother for cheap. About $100 bucks in this guy but I still need to finde some 1 1/8" blast gates and I have been looking around for a 2HP blower. Non of these systems will ever be perfect. Most of my wood tools are older and do not have the vacuum attachment ports so I have to fabricate most of them.
I also use these box fans with filters to capture some of the finer air borne dust, but as stated above none are perfect systems.

Jackfre · Jan 1, 2013

I'd try woodworkers forum and settle down for a bit of reading in the DC section. I have the little Oneida system and for a shop vac type system it does a nice job

bullnerd · Jan 1, 2013

Penn state ,I think thats the brand I copied.I built this before I had CL or the internet for that matter or I probably would do one of those cyclone dealys.

I built gates out of 1/4 ply.I cant belive the hot glue I used is still holding them together.

Impellar housing top and bottom is 3/4 ply wraped with thin SS sheet on the sides and held on with wood screws,covered with the aluminum duct tape.No pics of the impellar,this was back before that got popular.I do remember its very simple.1/4 aluminum angle riveted to an aluminum disk.I think I have the pattern somewhere for the vanes if anyone really wants it.

Plywood lid is just sitting on the barrel,when turned on it ***** down onto weatherstripping.

Low voltage switches turn it on.

Motor was sitting around at work about to be tossed so that was free.Only thing I paid for was the bag.

red73mustang · Jan 1, 2013

Thanks for all of the replies. Some of these whole shop systems look pretty involved and would take up alot of shop space. I was kind of thinking alon the lines of a more local type system that I could incorporate into my existing work bench or maybe some simple portable rig that I could attach to various dust generating saws. Does anyone have any ideas that involve a kind of of down-draft dust table that you could put a saw on top of that would capture the majority of the dust?

Voi · Jan 1, 2013

I got a free 4 HP (skeptical of that claim) three phase collector that some guy couldn't sell because it was from Italy and potential buyers were concerned they wouldn't be able to get it to work. It was used in a professional shop here in the states so I'm not too worried. And it was free.

I plan eventually plan to run it in an insulated closet and through a home made cyclone or Thein type separator. My fines will then be exhausted outside, which is allowed in my area. Whenever you can bypass a filter althogether the more effective your collection will be. The smallest particles are the hardest to collect and the worst for your health. With most filters you're just re-circulating those fine particles through your system and throughout your shop.

The VFD will allow me to fine tune the suction in case my larger chips are making their way past the separator.

But if you want to use an old wet-dry vac then you'll want to make a system that rolls from machine to machine. I haven't made one but there are a lot of plans using these along with home made separators. Some have even modified the openings in wet dry vacs so larger hose could be used.

If you can make both your machines and your system portable you could possible have the wet dry vac outdoors so you're not pumping fine particles back into your shop. But you'd want to do this with the shortest runs of hose or pipe possible so you're not limiting the suction at each machine too much.

Angelfire · Jan 1, 2013

If you are looking at truly collecting all the dust, particularly the fine particulates that lead to respiratory problems, you are going to have to pony up some cash. I've been following Bill Pentz's site for a few years now and will build a system based on his designs when the time comes. If you're just looking at making the area look clean, a shop vac with a cyclone trash lids works pretty well.

BWS · Jan 2, 2013

Very deep subject...so much that,I'd do it a misjustice to even try a synopsis.

Start with what you're trying to "clean-up"....and you can then start a plan.

Then I'd strongly suggest learning some sheet metal skills...along with an investment in tools/equip in that arena.Several years ago when I needed to expand our shops DC....the only place anyone would even give me the time of day,so to speak.....was here on GJ.The question was how to make a sheetmetal wye.....can't remember the guy(apologies),but it was like a litebulb coming on!And practice this craft almost daily since.

So,thats a start.....accurately describing what particulates,and then learning to roll you own sheet metal.Plastic and wood have EXTREMELY limited use in building proffesional units.

I call them "dump boxes"....don't know where it came from?Maybe its a real term,might be my imagination?But in any case......imagine a dishwasher sized box sitting on the floor.Near the top of it,a 4" duct comes in one side......opposite side theres another 4" duct.The airflow is obviously traveling through the duct....what do you think happens to the duct or line pressure when all of a sudden it hits that big open space?

Start study'n commercial designs on E-Bay......look for the dump bx style I halfass described above.

Aerodyne has some interesting engineering you can study as well.....looking at their horizantal "cyclone'ish".....very Nascar air scrubbers.Its a tube inside of a tube(albiet 10' in diameter)....with opposing air streams fighting it out....particulate is sort of magically "expressed" right the f**k out of the airstream.

TerryH · Jan 2, 2013

Hause said:
interesting reading on making your own here, he has plans too: http://billpentz.com/woodworking/cyclone/index.cfm

I actually worked with Bill years ago to help get the plans into a form that anyone could use to build a cyclone. I have built many of them. One of the best things I ever did was to build a cyclone and get my DC system to a level that it actually collects fine dust. There are several units available now that do a great job also. The bottom line is that you need a unit that has enough power to actually collect the finer dust and not just the chips, filters that will keep the fines captured, and you need a duct system that will flow enough air to support the collector.

JakeKohl · Jan 2, 2013

I just bought a Jet system with a canister filter. When I studied dust collection systems, every time I tried to find a way to save $100, it resulted in a huge compromise of some sort.

Also keep in mind that if you have a conditioned work space and are pumping the exhaust air outside, you are exhausting your conditioned air at a pretty high rate.

BWS · Jan 2, 2013

Had my breakfast and was looking at the egg carton..........

Two things this is mighty close to in model form.One is a "baghouse".....this would be on the exhaust side of impeller/cyclone.Imagine a DC bag hanging from each of the egg compartments.....this is instead of a cartridge filter.Has been used very succesfully.....and will continue to be used,in industry for well,ever.

The next way of looking at the egg carton is a little more complicated....to describe.Not complicated in use.And its engineering also is still in use.That is as a "multi-clone".......Its basically a bunch of smaller diam cyclones,housed in a large plenum.This is before the bags/cartridge filter.But there would be a small cyclone fitted everywhere the egg carton has a compartment.Google multi-clone.

egnorant · Jan 2, 2013

Fab up a mount for that grass catcher that you never use from the push mower.
Should catch most stuff.
Need more umph? Box it in and seal it tight with a shop vac port to create better flow and to filter out the stuff that gets past the grass catcher.

Bruce

Daddy454 · Jan 2, 2013

[/QUOTE]

Holy **** that is some serious dust collection!Nice work.Wish I had something even remotely like that.

Alaric.H · Jan 2, 2013

I use a duel motor central vac for the grinder cuts down on the rust clouds and metal sparks.

NUTTSGT · Jan 2, 2013

I made this just to try to contain some of thedust from the RAS.

It doesn't catch all but about 75 % of it and drains into a 5 gallon bucket.

TerryH · Jan 2, 2013

red73mustang said:
Thanks for all of the replies. Some of these whole shop systems look pretty involved and would take up alot of shop space. I was kind of thinking alon the lines of a more local type system that I could incorporate into my existing work bench or maybe some simple portable rig that I could attach to various dust generating saws. Does anyone have any ideas that involve a kind of of down-draft dust table that you could put a saw on top of that would capture the majority of the dust?

You can build a simple down draft box out of scrap plywood and peg board but it's probably more suited to sanding rather than saws. I use mine with the cyclone but it would work on a smaller scale with your shop vacs. Just basically a plywood box with angled bottom panels with pegboard on top.

Similar items are also available commercially from places like Grizzly Industrial, Rockler etc...

never enuf time · Jan 3, 2013

Pec, any chance I could see the other side of your blower ? I think I have one I can use from an old infatable slide.

PECVD2 · Jan 3, 2013

NETIME, Yes you could use many different blower/fan set ups. I have looked a bouncer inflators as well. This one was used by a floor guy for drying wet areas. It is only a 3/4hp so I am looking for 2 to 2.5hp motor/blower with a 6" inlet and outlet. But this set up works good even with 16 plus feet of corregated hose (not the best).

PECVD2 · Jan 3, 2013

NUTTSGT said:
I made this just to try to contain some of thedust from the RAS.

[It doesn't catch all but about 75 % of it and drains into a 5 gallon bucket.

NUTTSGT, I may steal your extended shroud idea. I have been considering a large RAS encapsulating type hood but like your slight extension shroud better than mine.

never enuf time · Jan 3, 2013

Thanks for the pics pecvd2, I may steal that idea.

Pathfinder · Jan 3, 2013

Google "Thein separator top hat". The top hat design is a refinement of Phil Thein's baffle separator. The top hat is more complex to build than the baffle, but the reviews are very positive.

John

Tim The Tool Man · Jan 4, 2013

PECVD2 said:
NUTTSGT, I may steal your extended shroud idea. I have been considering a large RAS encapsulating type hood but like your slight extension shroud better than mine.

Here is my contribution to the RAS dust shroud discussion. Mine has 2 spring loaded hinged flapper type doors that move out of the way as the saw gets closer. one on the top left and one to the right behind the saw body in my picture. the left side of my funnel set up is stationary.

PECVD2 · Jan 4, 2013

OP,

I hope I am inbounds and not hyjacking here but,
Tool Man please let us see some close up pics of your set up.

[/QUOTE]

NUTTSGT · Jan 4, 2013

PECVD2 said:
NUTTSGT, I may steal your extended shroud idea. I have been considering a large RAS encapsulating type hood but like your slight extension shroud better than mine.

Steal away if you like, that's why we post pictures here. One thing I did have to do the other day was bend the edge of the sheetmetal up. This was on the top side near the back. where the saw guard is.

I was using the RAS to cut some rabbets/dado and had to raise the saw. This was something I never took into consideration. Nothing major but keep it in mind if you build something in the like.

Tim The Tool Man · Jan 4, 2013

PECVD2 said:
OP, I hope I am inbounds and not hyjacking here but, Tool Man please let us see some close up pics of your set up.

Sure. First, though my model number didn't qualify and I had to fudge numbers, I got the free upgrade kit from Sears which comes with the new guard and top. I didn't use the top and instead built a sliding top to give myself a larger work surface:

The dust guard works as pictured below. Though my original inent was to have the ability to cut various angles with my RAS, I now only use it for 90* cuts and dados... My dust hood works far better than I had expected. Maybe once a year I run my shop vac behind the saw to pic up uncaught saw dust. I am very happy with it.

PECVD2 · Jan 4, 2013

^^^^^^^^^^ Is that the new/recall shroud that Sears provides? Mine is on recall I just have not responded. Looks like it might do a better job pulling dust off the top back and provide some additional support locations for the hose. I usually duct tape the stinger hose to my RAS and struggle with the hose being in the way. I am going to apply for the recall upgrade today plus the added safety factor might help keep my fingers attatched correctly.

PECVD2 · Jan 20, 2013

Installed the blade shroud and table I received via the sears recall. I picked up a reducing DC wye off flea bay and hopefully will be able to install that top DC pick off this week and a better rear DC shroud soon thereafter.

texasOFT · Jan 23, 2013

My system is a HF 2HP, added a canister filter on top and make a thein baffle (google thein baffle) top hat to fit on a trash can. 95% or more of the dust goes in the trash can and the filter canister is 1 micron to catch the small stuff. Still hooking up tools.

To build I dissasemble the HF dust collector, mounted the motor/blower asssembly on a shelf, plumbed the suction side down to the thein baffle with 5" vent pipe, plumbed the discharge to the collector - I replaced the top 5 micron bag with the 1 micron canister.

The thien baffle will work with a vacuum and a 5 gollon bucket or larger dust collector (bucket or trash can. Baffle good at keeping dust out of vacuum filter so you don't have to clean it so often.

McFarmer · Jan 23, 2013

I wired a couple old shop vacs so they turn on with the RAS and table saw. Then rigged an old dryer fan up to a box with a furnace filter to catch all the little stuff. Works good to circulate the air in my shop with a wood burner. I can't stand the noise of the central vac I had before.

ADSR · Jan 23, 2013

bob15 said:
I bought this a couple weeks ago. When attached to my shop vac it did a real good job of "catching" the sawdust and woods-chips and dropping them into the steel barrel that came with it. For $200, I think it was well worth it.

http://www.oneida-air.com/category.asp?Id={CC6B6F2A-E3D7-4F18-A53C-B5C357DFE131}

bob

That's kick ***!

Thanks for posting it!

Homemade or low buck dust collection systems?

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