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A new shop in the making #21: Putting in a dust collection system

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Blog entry by Bob #2 posted 11-19-2008 09:55 PM 4524 reads 1 time favorited 15 comments Add to Favorites Watch
« Part 20: Moving the machines and sorting the hand tools Part 21 of A new shop in the making series Part 22: A real test of the infrared gas heater »

As my odyssey continues, I have reached the point with the shop where I can install the dust collection conduit and hook it up to my new home built 2 hp cyclone.
The cyclone is styled after information obtained from the Bill Pentz website and although not an exact duplicate seems to work quite well.

From new shop

As you can see from the picture I split the system into two zones. One zone runs for approximately 22 feet using this six-inch spiral lock tubings for the mains four-inch drops to my tools.
The second zone travels across the width of my shop to the balance of my machines. That run is approximately 30 feet long. I tried to keep the conduits low along the wall in order to maximize the particle velocity entering the system from the tools. I found that the table saw and the bandsaw both required dual four-inch ports thus maximizing the capacity of my six-inch lines.

From new shop

I used saddle type connections to the spiral lock tubing as I found it impossible to buy sweep elbows locally.

This seemed to work just fine with a small amount of flex tubing between them and the blast gates.
I used an abrasive cut off disc on a small grinder and finished out the trimming by hand with tin snips.
The takeoffs were rivited in place and sealed from the inside with high heat silicone compound. I then taped the outside of the joints with foil tape to reduce the chance of a leak.

The compound miter saw became a bit more of a challenge as it wants to not only push sawdust off the blade from the top but also spreads it quite liberally off the bottom of the blade in a large fan shape.
To help with this I constructed this plastic cage allows the saw to rotate from 50° left to 45° right and also tilt to a 45° miter without interference. To get the shape pretty close I made a mockup template out of cardboard and refined that before I cut the final shape in coroplast.
Coroplast is quite rigid yet easy to bend and fix with wide flange sheet metal screws.
I think I will face the same situation with the Radial Arm saw later although I only kept it for dadoes so I may not build an elaborate trap like this one.

From new shop

The following picture. shows the position of the blast gate.
I am able to run a 2 inch flex tube up to the opening of the blast gate to direct most of the debris into the line.
From new shop
this picture shows a vertical gate to which I intend to look up a temporary four-inch line to run such things as a planer and jointer.
From new shop

This picture shows you the approximate position of the bandsaw along with its double extraction ports the new down draft sanding station that has yet to find a permanent home along the wall.
From new shop

I hope to be able to start sorting out most of my shop materials and tools now and find permanent homes for a lot of those things that are lying in piles around the room so today is a good day for me in that I have 90% of my dust collection hooked up and running.

Cheers

Bob

-- A mind, like a home, is furnished by its owner



15 comments so far

View Tony's profile

Tony

978 posts in 3494 days


#1 posted 11-19-2008 11:21 PM

Comming along nicely – we just had the first snow of the winter here, 3 weeks later than normal. I hope you get everything finished for those long cold, dark nights.

-- Tony - All things are possible, just some things are more difficult than others! - SKYPE: Heron2005 (http://www.poydatjatuolit.fi)

View pommy's profile

pommy

1697 posts in 3155 days


#2 posted 11-20-2008 12:05 AM

looking good mate i just open my doors for dust extraction lol!!!!!!!

-- cut it saw it scrap it SKPE: ANDREW.CARTER69

View CanadianWoodChuck's profile

CanadianWoodChuck

402 posts in 3377 days


#3 posted 11-20-2008 01:11 AM

Looks good Bob. I ran a very similar setup last year. I started with an 8” main header that fed 3 6” lines and then 4” drops to each machine from there. Did you configure anything around the drill press? I drill several pen blanks and would like some way to add the drill press.

-- Wood Chuck (Bruce) http://3dwoodworkingplans.com

View Bob #2's profile

Bob #2

3809 posts in 3485 days


#4 posted 11-20-2008 02:02 AM

Tony, we are not far behind you . -10 tomorrow but still no snow. \
It’s all around us though.
Yes, I have most all in and sheltered now so it can do it worst if need be.

Pommy, I envy you with the warmer climate but don’t you have other things to spoil it?
We are used to the weather changes and our lives revolve around them to a certian extent so it’s not like in the movies.
Bruce, I was just tryint ot figure that one out here before supper.
I am thinking about and air assist to move the chips to the intake.
Do you have air in you shop? Air can be your friend hen the pipes fial you.

Cheers

Bob

-- A mind, like a home, is furnished by its owner

View Thos. Angle's profile

Thos. Angle

4445 posts in 3426 days


#5 posted 11-20-2008 02:30 AM

I been gone, Bob. I didn’t even know you were building a new shop!!! Now I’ll have to go back and read all about it. This all looks well thought out.

-- Thos. Angle, Jordan Valley, Oregon

View Bob #2's profile

Bob #2

3809 posts in 3485 days


#6 posted 11-20-2008 03:05 PM

Hi Thom.
It’s been quite an adventure.
I started blogging this back about May 28th and felt I should finish it .
(an obligation to myself) <g>

Cheers
Bob

-- A mind, like a home, is furnished by its owner

View Bob42's profile

Bob42

456 posts in 3254 days


#7 posted 11-20-2008 03:47 PM

Looking good!!

I am waiting for my new dust collector to come. I have a one car garage that is my shop and the car will not go in it, so I am going to renovate it this winter. I was looking at the spiral ducting but, it’s very expensive. Not sure if I will use some heavy gauge a/c duct that I can get cheaper and locally. For the meantime when my dust collector come I will use it as a portable.
I am curious how you will make the box for the radial arm saw? I have one too.

Please post the completed shop when it’s done.

-- Bob K. East Northport, NY

View Bob #2's profile

Bob #2

3809 posts in 3485 days


#8 posted 11-20-2008 04:29 PM

Hi Bob42:

I found the spiral pipe fairly reasonable . I believe it was about $23.00 a ten foot length here. The prices of PVC have gone up dramatically making it a distant second choice. Try your local HVAC supplier. That’s what ii did here and they were quite helpful.
The shroud/box on the CMS was time consuming as I had to make up a pattern from cardboard first then transfer that to a piece of 1/3” MDF base.
I cut strips to follow the curved edge and glued them in place
Coroplast is available from sign shops and I see Home Depot carries it too. It’s like plastic cardboard so you can cut it with a knife. Make sure the holes in the sheet for curves go parallel to the curve not vertical or it will kink on you.

Cheers
Bob

-- A mind, like a home, is furnished by its owner

View Lee A. Jesberger's profile

Lee A. Jesberger

6819 posts in 3443 days


#9 posted 11-20-2008 05:17 PM

HI Bob;

Looks like the shop is getting smaller!

The dust collection system looks like it well really make a difference.

I don’t know if you use them, but I find the dust collectors / air cleaners that hang from the ceiling, and clear the dust from the air, to be very helpful as well.

I have a couple of them hanging in the shop, (splitting the shop in thirds), and they clear the air pretty well.

In fact, when it was time to go to lunch, one of my workers used to take a long wand air gun, and blow the dust off of everything in the shop, including shelving and cabinet tops. (He was wearing a mask when doing this). By the time we got back from lunch, the air was clear, and the shop was clean.

The first time I saw him doing this, I was about to go off, but he said that’s how he always does it. I did know that whenever it was him that cleaned the shop, it was surprisingly clean.

Lee

-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com

View Tony's profile

Tony

978 posts in 3494 days


#10 posted 11-20-2008 09:32 PM

Hi Bob

We have just come to the North of Finland to do a little skiing – 24°C to night and a high of -19°C tomorrow.

Anyway have you found a big difference with the cyclone vs the standard dust collector for a similar power i/p? Any links or plans for the cyclone you have built?

-- Tony - All things are possible, just some things are more difficult than others! - SKYPE: Heron2005 (http://www.poydatjatuolit.fi)

View Bob #2's profile

Bob #2

3809 posts in 3485 days


#11 posted 11-20-2008 10:29 PM

Beautiful weather for cross country but a bit cold for downhill for my old bones.
I’m going to try to get out this year as well.
As for the differnec evs bag and filter and cyclone:
For me it has been very good. I built a smaller one before this for a 1 hp machine and it was amazing how much more dust I picked up. I’m not talking about wood chips but real dust that kills your lungs.

The “plan” I used was a basic design by Bill Pentz . The vanes of the impeller are cut from Aluminum and bolted to a plate. -Diam 14 ” ( 37 Cm)
I used and industrial Baldor HP motor TEFC to handle the on and off switching that goes with this craft.
In addition, I feel I get a full horsepower rating with these motors.
I used a standard chemical processing drum with ribs to from the body and just dropped the funnel off the bottom. There is a spiral ramp inside the barrel to move the debris into a circle as is drops down the funnel.
by the time it reaches the bottom it is traveling faster than the return air and the separation is almost complete.
I used an over sized felt bag on this one to decrease back pressure and allow the air a chance to seep through back into the room.

Most of my inspiration comes from a Buddie of mine and he has complete instructions at this site

This other “bible sight” is the one that Bill Petnz put together .

here .

Steve is very approachable so if you want morn technical info don’t be afraid to email him and tell him I referred you.

Cheers
Bob

-- A mind, like a home, is furnished by its owner

View Bob #2's profile

Bob #2

3809 posts in 3485 days


#12 posted 11-20-2008 10:35 PM

HI Lee: Thanks again for the encouragement. You are right the palce is shrinking right now. I will be so happy to get everythin put away and get some proje4cts going again.
Good poin abou the overhead air scrubbers. I had one until the move and it got dropped and is now trash. I have a couple of decent motors her so given a few extra minutes I will rebuild it and put it on a timer like the old one. I usually use the air line to “dust” at the nd of the session anbd let the filter deal with the fines when I’m gone.
I face my ccrubbers with filter cloth and just toss it out when it get brown. The filters just slow the dust down so it can stick on the filter cloth.

Cheers
Bob

-- A mind, like a home, is furnished by its owner

View Karson's profile

Karson

35035 posts in 3864 days


#13 posted 11-21-2008 05:27 AM

It looks great Bob. And I think I’ll take Lee’s suggestion and try to get some of the dust moving when I’m not around.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware soon moving to Virginia karsonwm@gmail.com †

View Bob #2's profile

Bob #2

3809 posts in 3485 days


#14 posted 11-21-2008 05:59 AM

Hi Karson. I’m thinking the same are you re the extra scrubber and usng it on off hours.
I am thinking about exhusting it into the 6” spirlok piping so when I turn the DC on it will end up in the DC trash can and save one more machine to clean.

Bob

-- A mind, like a home, is furnished by its owner

View Bob42's profile

Bob42

456 posts in 3254 days


#15 posted 11-23-2008 02:19 AM

Hi Bob,

Thanks for the info on the pipe, I do get a large discount at the local HVAC thanks to a friend. I will try that.
Thanks again and good luck with the new shop.

-- Bob K. East Northport, NY

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