"We have a 1.5HP Jet single stage with the filter. It is going to be dismantled and converted to a cyclone shortly using a one-piece molded plastic cyclone"
Same unit, I converted mine using the older steel cyclone, they're now white instead of blue - I'm limited ATM to 30 amp 240, so the smaller cyclone lets me use my powermatic saw (or planer, or jointer, or band saw, or routers, etc) AND the DC that way.
4" pvc, no 90's, as little flex hose as possible, etc, and it works. I'd also prefer at least 6" and 3 horse, but need a separate shop for metal work MORE, so "LABTYD" (Life'sABitchThenYouDie :=)
I built the stand so the black foot pedal LOWERS the barrel just enough to clear the lid - there are stops behind the barrel, so once it's emptied I just push the barrel back til it stops and step on the pedal. Gives just enough lift to slightly crush the foam tape lid seal - Done.
For now, in the interest of flexible use, NOTHING hangs down far enough to hit my head when tools are disconnected and rolled out of the way... Steve