Fighting Dust #1: Dust Collector Mods - Phase II

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Blog entry by ChunkyC posted 12-29-2009 05:04 AM 2061 reads 2 times favorited 7 comments Add to Favorites Watch
no previous part Part 1 of Fighting Dust series Part 2: Tablesaw Overhead Dust Collection »

I finally got around to Phase II of my HF DC Mods. Thanks to DBHost for the help!!! I contacted DB about his conversion but I quickly learned that he had the type of barrel that the lid is removable.

I got a blue barrel from work but it’s the kind that you have to cut the lid off. :’( So that caused me all sorts of “issues.” The biggest problem was how to cut lid off and keep the top flat. I never solved this problem so I worked around it.

(This picture doesn’t do the problem justice. It is 1,000x worse than the picture shows.)

So I cut the top off and then used a router, file, rasp, sand paper, et al to clean the edge the best that I could. It got better but it still leaked like a sieve.

So I glued up a piece of 3/4 MDF and 3/4 ply and use the router with a trammel to make a big “gasket.”

I can’t say enough about how well this works. I expected an improvement but I didn’t expect it to completely seal the edge. But I got a tube a silicone today anyway at the hardware store that I’ll use to seal the gasket to the top of the barrel permanently.

For the top and baffle, I used 3/4” ply and 1/4 hardboard. The fittings are a ‘universal 4” adapter’ and a normal 4” DC hose 90 that are held in place with silicone. I used these because it solves the problem of trying to adapt to PVC to hose. And there’s a tool store here in the small (tiny) town that I live in that carries a very wide assortment of fittings. YEAH ME! ;D

So for the eagle eyes among us, you may notice a blast gate on the suction side of the barrel. This is by design because I have a ‘Y’ at the DC that I use as a bypass of sorts. Also, it’s the only way that I have found to go from 4” sewer PVC pipe to 4” hose.

The 4” PVC to DC Hose fittings are for schedule 40 DWV NOT sewer pipe! If you know how to transition from sewer pipe to hose, I’d love to hear from you!!

I should mention that this is a “The Thien Cyclone Separator Lid w/ the Thien Cyclone Separator Baffle” Modification.

-- Chunk's Workshop pictures:

7 comments so far

View Jimi_C's profile


507 posts in 2654 days

#1 posted 12-29-2009 06:26 PM

Very nice.

-- The difference between being defeated and admitting defeat is what makes all the difference in the world - Upton Sinclair, "The Jungle"

View drfixit's profile


318 posts in 2563 days

#2 posted 12-29-2009 06:43 PM

i’m using the same type of set up… but I used a trunklid gasket from a totaled car to seal the drum, it has a stiff channel that the top of the drum fits in, then the soft rubber seal on top,

-- I GIVE UP!!!! I've cut this @!&*!% board 3 times.... its still too short!

View JamesVavra's profile


298 posts in 2735 days

#3 posted 12-30-2009 01:06 AM

I’m in the process of building one of these too. I thought I got a pretty clean cut around the top but I haven’t gotten too far on the project. I’m hoping to get some time to work on it this weekend. You’re “gasket” idea is great though.


View drfixit's profile


318 posts in 2563 days

#4 posted 12-30-2009 04:41 AM

Couldnt post pics at work… heres a pic of my trunk gasket…

-- I GIVE UP!!!! I've cut this @!&*!% board 3 times.... its still too short!

View ChunkyC's profile


856 posts in 2674 days

#5 posted 12-30-2009 05:37 AM

Awesome! I wish I had one. Actually, mine seals up pretty well now that I’ve made the wood gasket and used a tube of silicone to seal her up. I did find one leak where one of the layers of ply had delaminated and left a small void. I little wood filler and a quick sanding and shes a good as gold.

I like your 90! Looks very familiar. lol

-- Chunk's Workshop pictures:

View drfixit's profile


318 posts in 2563 days

#6 posted 12-30-2009 07:47 AM


-- I GIVE UP!!!! I've cut this @!&*!% board 3 times.... its still too short!

View dbhost's profile


5590 posts in 2651 days

#7 posted 02-22-2011 04:35 AM

Good execution! I love how mine works!

-- My workshop blog can be found at

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