Dungeon to Lair: That's the plan at least... #22: The- To- -at & a Router Circle Cutting Jig...

  • Advertise with us
Blog entry by DIYaholic posted 03-02-2013 04:08 AM 4326 reads 1 time favorited 5 comments Add to Favorites Watch
« Part 21: If At First You Don't Succeed.... Part 22 of Dungeon to Lair: That's the plan at least... series Part 23: Thien Thing (build), Different Day... »

I HATE moving the DC hose from machine to machine!!!

One of these days (who hasn’t said that tooo many times?), I will be running 4” galvanized metal ducting throughout the shop. I’ve had the ducting for a while now, but am waiting to install it until my machine layout is better determined. I also need to do the obligatory HF 2HP DC Thien Top Hat upgrade. I already have the Wynn Environmental 35A-NANO cartridge filter. The DC upgrade will go a long way towards the “Dungeon to Lair” metamorphosis!!!


I got fed up the other day after wasting too much time relocating the DC hose and tripping over it waaaaay too many times. So I have started a Thien Top Hat & Tails build in conjuction with a HF 2HP DC modification!

I wish the title to this blog installment could have been:
Thien Top Hat & Router Circle Cutting Jig, but the Thien Top Hat is incomplete!!!

Here are pictures of my very limited progress. I blame the slooooow progress on having to move the DC hose from machine to machine and the fact that I had to first make a router circle cutting jig. That may or may not be totally true, but that’s my story &.......

I didn’t have any written plans, just drew it up on the ply, “on the fly”! I used my crappy Skil jig saw & my RIKON 10-325 14” BS with a 1-1/2HP motor and 13” of Resaw Capacity to rough out the shape and cleaned up the edges with my new router circle cutting jig.

The circle jerk, err jig build, was a “Down & Dirty” git ‘er done kinda thing. I used what I had on hand & built it quickly. OK, quick for me anyway!!!

Router Circle Cutting Jig cleaning up!!!

Test fit on the bigger than a “10 Gallon hat” trash can!!!

The bottom section “Thien Baffle” and the top of the “Hat” piece:

That’s what I done did today.

I am soooo looking forward to having ALL my machines ducted and NOT tripping over DC hose!!! Hopefully, tomorrow’s weather forecast is accurate and we will see very little snow. I won’t have to plow and I’ll then be able to make some more progress.

Well, that’s the plan at least!!!

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procrastination a bad thing?

5 comments so far

View JL7's profile


8646 posts in 2933 days

#1 posted 03-02-2013 04:35 AM

I built the Thein baffle a couple of years ago, but it seems like the width of the cutout area was wider than you have there….opps…..never mind…..I get it now. I built the one inside the collector and you’re doing the trash can separator….good call. This will be a great addition. I added the super dust deputy to my single stage collector and it just rules… chunks of maple flying though the impeller any more…..and no more changing that nasty bag…...I can empty the drum in less than 5 minutes and that includes hauling it up the steps to dump it. I got a spare lid for the drum so it’s mostly dust free to get it out of the house….

Looks like the circle JIG is simple and effective…..

I guess you earned a cold one today…...nice.

-- Jeff .... Minnesota, USA

View DIYaholic's profile (online now)


19597 posts in 2643 days

#2 posted 03-02-2013 04:50 AM

There is a great build thread, on another website, that I used as inspiration. I used his “dimensions”, kinda sorta. Should there be a need to widen the 1-1/8” – 120 degree opening, it will be easy to do. Making that opening smaller would prove more difficult!!!

The jig IS veeeeeery simple. How else do you think I could make it in one morning!!!

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procrastination a bad thing?

View Dave's profile


11429 posts in 2808 days

#3 posted 03-03-2013 02:44 AM

What is this you are building Randy?

-- Superdav "No matter where you go - there you are."

View William's profile


9949 posts in 2810 days

#4 posted 03-05-2013 01:19 AM

I thought you were building a router circle jig.
Then I realized it was dust collection.
I buy my dust collection by the pack.
I just suck all my air through cigarettes.

Seriously though,
Glad it’s coming along good for you.
I may add dust collection if I ever win the lottery (which I don’t play).
I’m one of those old school fellas that realizes that all the crap and asbestos I’ve sicked down my lungs over the years working on cars, and industrial equipment, that wood dust probably won’t be what does my lungs in.
It’ll be either my past work experience or the pack a day habit of nicotine.
So dust collection isn’t exactly high on my to do list.

I enjoy watching other’s home made builds though.


View DIYaholic's profile (online now)


19597 posts in 2643 days

#5 posted 03-10-2013 03:36 AM

Sorry for the late reply.I must have nodded off!

It is a Thien Top Hat for my HF 2HP DC. For the build I needed a circle cutting jig for my router. So I whipped together a “down & dirty” jig.

You think my pack a day habit is UNhealthy???
I hear ya regarding all the other contaminants that enter our lungs.
Well, at least I won’t have to sweep as much!!!

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procrastination a bad thing?

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics