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In Ceiling Air Cleaner #1: An air cleaner that you won't walk into...

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Blog entry by chopnhack posted 03-11-2013 07:49 PM 1527 reads 2 times favorited 0 comments Add to Favorites Watch
no previous part Part 1 of In Ceiling Air Cleaner series Part 2: Completed »

Well, it all started out with a trip to buy an air cleaner off of craig’s list some time ago. I saw a used Jet AFS-1000B for sale for about $150. After checking out the spec’s, I thought, gee, this would work great, 30×24x12, that’s not too big, I can find a place for it…. Drove about 1.5 hours round trip to discover that hey 30×24x12 is actually too BIG! I imagined myself hanging this thing near the step down that I have entering my garage and knocking myself in the head (exaggeration :-) But I seriously didn’t see myself hanging this overgrown paperweight from the garage ceiling anywhere. It didn’t look right up there and I could imagine having interference with projects. The garage height is about 8’ and I have knocked into the ceiling a few times already.

So the idea gets in my head, that hey, why not just build one yourself and tuck it up in the attic space above the garage…. hmm…...

The research begins with some reading into air flow, HVAC principals, scroll cage designs, ductwork designs, etc. Got into the deep end and had several long conversations with an HVAC engineer and after a while the information started to come together into manageable blocks.

The next step in my work was designing the ductwork and boxes to contain the filter and motor. After getting a used blower motor from a pal (Thanks ABC Air Conditioning!!) I tested out the unit to see what air flow it could give me at its no load speed. From there I was able to design the appropriate filter size, box sizes and ductwork size.

Here is a sketchup of the placement. You are looking down at the top of the attic space. The two 90’s are flexible elbows that can rotate. 10” flex hose connects them to the diverter box (the pyramid shaped item with two 10” holes).

The sheet metal to make the boxes was very inexpensive, perhaps $28, it was all usable drops from the local steel supply, mostly 26 gauge and some 24 gauge. In total there was two 18×24x5 pans for the supply air, these were covered by 24×18 stamped metal grilles, one 24×24x20 air filter box, one 20×19x24 motor housing and of course the pyramid shaped diverter box – 24×14x6.

Big thanks to TomSlick from http://www.bt3central.com/ for helping me with the layout on the pyramid! With his help I was able to fold that complex shape out of one sheet of steel.

More pics to follow.

-- Sneaking up on the line....



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