Dust deputy cart.

[Firebrick43]

Maybe a year or so ago I bought a dust deputy cyclone to go between my ridgid 6.5hp shop vac. Really a game changer in how little dust gets to the shop vac and how little cleaning/replacement of filters is needed. Problem then became keeping the damn thing upright. Well I have a LOT of sanding to do and it's nearly dust free if the vacuum/cyclone is hooked up so I decided to make a cart.

So I needed to build a cart. Looked at the "Shops Notes" plans and similar but take quite abit of cutting and would need some decent ply to boot. So I came up with this fast and cheap, but still extremely stable and sturdy cart.

Had a quarter sheet of 1/2 ACX with one good face and one crappy face so that was the start. Cut the sheet to two 23" squares. Had some 2.5"~ wide scraps from some 3/4 pine 1x10's that I had ripped for stair risers(could not get clear 1/x8's). They were quite nice and quarter sawn. Ripped to 2-1/4" wide.
Used Kreg jig to pocket screw together the sides and some GRK screws (and glue) from the bottom to attach the ply.

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The corner braces were sized to allow 1-1/2 emt to fit snugly. The only difference between the top and bottom box is the holes in the bottom of the top box. This was done with a hole saw after making the box and was easy as the triangular pockets guided everything.

 

[Firebrick43]

I had most of a stick of 1-1/2 emt and another piece that was 29". So I cut two legs to 29"(front) and back ones to 35"

Before assembling legs and boxes I painted the boxers gray with some acrylic porch and floor paint (dutchboy) in battleship gray.

The boxes are attached with three TEK screws in each corner
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I think 1" emt would work fine, I was using up scraps.



View media item 85177I also had a 90 and a union for 1-1/2 emt so I bought another 90 and two unions and made a handle. Had to trim the 90's on one leg due to width

 

[EOC_Jason]

I like that, I've been needing to do something similar as I'm almost always using my vac with the DD.

 

[ScottsGT]

I built one last year that sits on a 5 gallon steel bucket. I used Jeep hood latches to hold the bucket down. It stands alone from the vac and has an arm the dust hose for power tools attaches too. Also mounted a power relay box that turns on the vac when the tools are turned on.

 

[Firebrick43]

2" schedule 40 PVC is the tube. Long sweep 90's keep the velocity up.
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A 2" strap clamp and a #5 strut clamp hold the pipe.
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A scrap shims out the strap clamp to keep the pipe plumb and 1/4-20 knobs reclaimed from an old fixture allow quick clamping/ unclamping to dump the bucket. It also has enough structure to support the top of the cyclone and keep it from bending or leaning

The short piece above the cyclone was heated with a heat gun and and forced over the cyclone inlet. This flared it to match and provides a good fit/seal

 

[Firebrick43]

A 2" to 1-1/2 adapter is used to adapt to a flexible wire supported hose that came in the cyclone kit. The adapter OD is slightly large so I glued a short piece of 1-1/2 pipe into the ID. I then used my lathe to machine half of the adapters OD off and half of the pipes is out to prevent flow from choking to much.
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I bought some three inch casters, two ridgid and two locking swivels. The roll even better than the original shop vacs casters and and is super easy to roll. Handles make steering a breeze. I have 25$ in casters and 20$ in other items but as mentioned most of the stuff was scrap from other projects which was good to use it up and free up space

The top tray will allow me to store vacuum tools and my sander.
Trying to decide if I want to just add a cord wrap or wire a 20' cord and box so I can plug the sander or my tracksaw into the cart while using them?

Overall it was a nice project and wish I would of done it sooner. Time to complete was an evening (if you don't count paint drying time).

 

[Firebrick43]

I built one last year that sits on a 5 gallon steel bucket. I used Jeep hood latches to hold the bucket down. It stands alone from the vac and has an arm the dust hose for power tools attaches too. Also mounted a power relay box that turns on the vac when the tools are turned on.

Please post a pic! (as well as anyone else whole wishes to)

How/what is the relay and how is it wired. Thanks!

 

[larry4406]

Firebrick43 - nicely done! Thanks for sharing. I am struggling with this same issue and have the same positive experience with the Dust Deputy.

 

[OccupantRJ]

Nice build there, Firebrick! Several items taking the floor space of one is key in a smaller shop, and this gets it done.

 

[ddawg16]

I like what you did.

I have the Rocker version of the dust deputy....it WORKS!

Right now I'm still using my shop vac....but in between projects, I'm working on a dust collection system. I have the HF small dust collector.....I just need to run some ducts now. I just picked up my blast gates....

Table saw with the dust dep is not an issue....but my biggest mess is the compound miter and radial arm saw

 

[southalabama]

That looks good.

I can't even keep a shop vac upright.

 

[MO-Iron]

I made this a few years ago and like how it has performed. The unit slides down on the vacuum original wheels and locks on with a tapered split ring that works like a trucks split wheel rim. I can still use the setup for a regular vac by simply unplugging the hose.

 

[Daedalus]

Thanks for posting guys. Very nice.

 

[Firebrick43]

I made this a few years ago and like how it has performed. The unit slides down on the vacuum original wheels and locks on with a tapered split ring that works like a trucks split wheel rim. I can still use the setup for a regular vac by simply unplugging the hose.

Your design certainly accomplishes the most with the least material. No hardware needed at all

 

[Firebrick43]

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Added 3 pieces to keep the bottom of the bucket in place. Putting a self adhesive disk on the bucket itself will give you the perfect radius.

View media item 85333Added plug and switch to the front.

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The switch only operates the receptacle that the vac is plugged into. The one on front and the other half of the bottom one are live all the time. I looked into the switches that start the vac when the tool comes on and decided I would pass due to money and also a large amount of the time the cart will be on the miter saw. I really don't want the vac starting/stopping every 5 secs with the saw.

A 15' 12ga extension cord was installed to the back of the bottom box with seal tite connector. At 15' it will handle a 20 amp load. Some 3/8 tubing was bent and screwed to the back edge to wrap the cord around.

 

[acer66]

Wow, that looks very good and well thought out, I especially like that you used no fancy stuff and made it work with what you had and off the shelf stuff.

Puts mine to shame.

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[Firebrick43]

Wow, that looks very good and well thought out, I especially like that you used no fancy stuff and made it work with what you had and off the shelf stuff.

Puts mine to shame.

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There is no shame in in yours. It works doesn't it? I sometimes get carried away with things .

The only thing I would suggest is buying some better casters. Looks like your using the ones that came with the kit? I tried them first but stepping up to some medium duty 3" casters made a huge difference.

 

[LXCam]

That's slick OP, nice job!

 

[acer66]

There is no shame in in yours. It works doesn't it? I sometimes get carried away with things .

The only thing I would suggest is buying some better casters. Looks like your using the ones that came with the kit? I tried them first but stepping up to some medium duty 3" casters made a huge difference.

Yes, thank you and good eye, those are the casters which came with the kit.

I had the vacuum on the bottom first but it fell over one to many times
and this way there is no issues with that and I will put bigger casters on there since these are stopped by almost everything.

 

[Firebrick43]

Small update. I had been planning a piece of wood with appripriat hole drill to hold attachments. The bad side would be that every attachment would need a custom hole and any change would require remaking it.

The last few weeks I have been playing with my new 3D printer. These post were drawn up on sketch up real quick and printed in gray petg.

I think they turned out well.

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[acer66]

Those look great Firebrick43.

 

[Jeff Ivers]

Nice job on that vac cart!

 

[CKS1955]

Looks great.

Jay

 

[Jay H 237]

Nice! Perfect timing too as I have the Dust Deputy sitting in my Amazon cart but haven't pulled the trigger yet. It has great reviews but wasn't sure if I really needed it but seeing this and hearing how it works it will be one of my next purchases.

Seeing the castors tucked under the pail on it makes it look a little unstable and I was looking at buying a 5 gallon pail castor dolly for it to sit in with the castors more outboard.

 

[Firebrick43]

Nice! Perfect timing too as I have the Dust Deputy sitting in my Amazon cart but haven't pulled the trigger yet. It has great reviews but wasn't sure if I really needed it but seeing this and hearing how it works it will be one of my next purchases.

Seeing the castors tucked under the pail on it makes it look a little unstable and I was looking at buying a 5 gallon pail castor dolly for it to sit in with the castors more outboard.

The casters included with the dust deputy kit are junk and the foot print of the bucket is so tippy that it's completely unstable. They expect you to drill your shop vac and bolt the outer bucket to the vacuum with a stiff foam block in between.

That's why so many do make a cart. A much wider bucket dolly would help significantly but pushing around two seperate items and not having the connecting hose disconnect is frustrating.

 

[Firebrick43]

Made some improvements.

3D printed some corner covers
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In the front left corner I welded some steel to some split collars to make a swinging drawer. Before welding them to the plate I bolted 2 washers on each side between the halves and bored out the inside diameter to .010” over the pipe OD. The third split collar is unaltered and keeps the drawer up in place.
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Keeps all my sanding disc at hand and separated into different grits. Since I always have the RO sander on the cart I was wasting a lot of time getting disc and running out of certain grits as they were all in a pile in the sanders soft case on a shelf.

Tomorrow after I get a second coat of paint on I will post pics of the sander dock.

 

[Mr onetwo]

I like the idea of the slide out bucket on this one...

https://www.instructables.com/id/DIY-Cyclone-Dust-Collector/

 

[ddawg16]

I LIKE that swing out sanding disk holder

 

[mcmlvif100]

Nicely done. Somehow missed the original posting so am glad for the update.

 

[clubairth]

I wanted everything mounted to my blast box. I built my own blast box and used angle iron to hold my VAC-50 vacuum and my Dust Deputy. Also keep my refrigerated air dryer under the blast box.

Please ignore the blue bag on the final air outlet. That was an experiment that failed and I now plumb the exhaust outside my shop.

What I like about this setup is with my blast box on casters I can roll the entire thing anywhere I want to work or just to get it out of the way for a big project.

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[info2x]

Looks good. I love my dust deputy. Allows me to keep those higher end filters in there without them clogging up after a day.

 

[Firebrick43]

As promised pics of the sander dock. Made from all scraps of ply and some aspen(tried it and it chips out something fierce so I will not buy it again)

Sander was rock solid but with the weight of the hose if you caught it it would cantilever the sander up and out. The hose support on the outside solved that.

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[BukitCase]

looks really good; how did you do that tapered half-moon trough to clear the outlet attachment? ... Steve

 

[Firebrick43]

looks really good; how did you do that tapered half-moon trough to clear the outlet attachment? ... Steve

Spindle sander with board tilted at an angle from upright.

http://https://www.garagejournal.com/forum/showpost.php?p=7315521&postcount=590

 

[niget2002]

I saw a similar holder that hung the sander by the top part. It allowed you to hang the sander right after turning it off without having to wait for the sander to stop spinning.

Sent from my LM-G820 using Tapatalk

 

[Firebrick43]

I like the idea of the slide out bucket on this one...

https://www.instructables.com/id/DIY-Cyclone-Dust-Collector/

I certainly like the idea of how the bucket is emptied. Does look like the cart needs some additional reinforcing as it jiggles as he moves it in the video.

I wanted everything mounted to my blast box. I built my own blast box and used angle iron to hold my VAC-50 vacuum and my Dust Deputy. Also keep my refrigerated air dryer under the blast box.

Please ignore the blue bag on the final air outlet. That was an experiment that failed and I now plumb the exhaust outside my shop.

What I like about this setup is with my blast box on casters I can roll the entire thing anywhere I want to work or just to get it out of the way for a big project.

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I will have to keep that in mind. I would like a blast cabinet out in the pole barn some day. Although a good buddy got a vapor hone and I am going over to his shop next week to take a look!

I saw a similar holder that hung the sander by the top part. It allowed you to hang the sander right after turning it off without having to wait for the sander to stop spinning.

Sent from my LM-G820 using Tapatalk

That interesting! Never seen that style. I plan on adhering a rubber pad as most commercial docks do that.

 

[Firebrick43]

7 years and is mostly still going strong and still my most used tool in the wood shop.

8 year old daughter loves to help clean up so she uses it a lot. Because of her height she broke one of the tool holders as it didn’t clear before she pulled on it

I guess I never uploaded it so here is a redesign, drawn in fusion, and put it on printables

Amazing how much better prints are designed in fusion and printed on the railcore compared to the old ender 3

Ridgid premium car cleaning kit attachment storage by Firebrick43 | Download free STL model | Printables.com

 

[Mike65]

I built one similar for my woodworking shop.