8-6-6 Wye

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Project by klipper posted 05-03-2011 11:22 AM 4226 views 7 times favorited 19 comments Add to Favorites Watch

There are lots of beautiful projects on this site, but this isn’t one of them. However, it is a very useful solution to a problem.

In 2010, I installed a ClearVue Max Dust Collection System in my workshop. It is a great system. It can handle two six inch runs simultaneously. It has an 8” diameter inlet and you need to install a 8-6-6 Wye to convert the 8” diameter pipe into two 6” diameter pipes. I decided to use 6” “sewer and drain” PVC pipe for my ducts as it is thin walled, light weight, easier to handle and the least expensive option for smooth walled ducts, which is critical for keeping the air flow up over long runs. Finding the PVC pipe turned into a real challenge, but finding a Wye with the right dimension turned out to be impossible. I spent a lot of time looking for one that would work. I did buy a metal pant wye at McMaster-Carr but the diameters were off enough to make it unusuable.

I finally had a novel idea. Why not make it out of wood. So I set out and drew up some full scale plans, keeping in mind the need to have the 6” legs at 90 degrees, a large radius curve to reduce drag, a smooth inner surface and lands on the inside of the adapter against which the PVC could seat. I decided the easiest way would be to make it from a series of segments glued together, instead of carving it out of a single block. Some decisoins are easy!!! I realized that, except for the very top and very bottom piece, I only needed to design 1/4 of the project. The other sections would be either identical or mirror images. I made patterns for each of the pieces. There are 50 pieces to this puzzle but due to symmetry, there are only 13 unique shapes.

I chose cedar for most of the pieces due to its light weight. I used oak on a bias for the top and bottom pieces for extra strength across the seam. Using the full scale pattern I had made as a gluing template, I glued up each quarter section, one piece at a time to ensure alignment. I didn’t want to use brads to hold the pieces in place, as I was going to have to smooth the inside and outside surfaces. When the quarter sections grew up to the point of mating, I glued two quarters together, to assure a good fit along the top and bottom seams. Establishing a good fit in the crotch was important as well.

When I had the two halves in place it was time to smooth the inside surfaces with gouges, rasps and a small rotory sander. I then used West Systems Epoxy to coat the inside of the halves to give the surface some protection against abrasion. Cedar is light but it is soft. With that done, I glued the two halves together, smoothed the outside and applied epoxy to the outside as well, using fiberglass reinforcement on the openings, where the most of the stress would be. And finally, I made a circular pattern as a guide and used a router to cut the correct inside diameters of the openings.

It was a lot of work, especially the hand smoothing of the inside, but it does the job I needed and makes a great conversation piece when I have new visitors to the shop.

-- Best Regards, Dennis

19 comments so far

View Dennisgrosen's profile


10880 posts in 3082 days

#1 posted 05-03-2011 12:10 PM

wrong its a beautyfull and function in one piece it can´t bee better when it solve a problem too :-)
thank´s for sharing the idea

take care

View Chris Davis's profile

Chris Davis

1558 posts in 3949 days

#2 posted 05-03-2011 02:34 PM

That is pretty awesome!

-- Watch live video from our shop.!current-projects/c3c1

View Bertha's profile


13521 posts in 2660 days

#3 posted 05-03-2011 03:13 PM

My hat’s off to you. Now you can admire your dust collection fittings. I wish I could say the same for my shop!

-- My dad and I built a 65 chev pick up.I killed trannys in that thing for some reason-Hog

View Jim Finn's profile

Jim Finn

2647 posts in 2888 days

#4 posted 05-03-2011 03:23 PM

Amazing! When I was a Sheet Metal worker making fittings like this we called an ,on the centerline split, like this a “pair of pants” and it was uncommon because it is difficult to make. Usualy we made a Wye with one leg streight and the other at 45º to it. (Much simpler to make) TO do this in wood is just amazing. Thanks for posting this.

-- Website is

View longgone's profile


5688 posts in 3275 days

#5 posted 05-03-2011 03:59 PM

That is really nice and obviously alot of work…but what the heck, we are woodworkers and making something unique is fun.

View shipwright's profile


7966 posts in 2764 days

#6 posted 05-03-2011 05:34 PM

Very cool solution.

-- Paul M ..............If God wanted us to have fiberglass boats he would have given us fibreglass trees.

View William's profile


9949 posts in 2809 days

#7 posted 05-03-2011 10:16 PM

View Jack_T's profile


623 posts in 2998 days

#8 posted 05-04-2011 12:34 AM

When I looked at the front picture I did not get what it was, even with the name. I was thinking abstract art. It is quite a nice piece of woodworking. A brilliant solution to a difficult problem. Congratulations on your solution.

-- Jack T, John 3:16 "For God so loved the world that he gave his only Son, so that everyone who believes in him might not perish but might have eternal life."

View jumbojack's profile


1674 posts in 2591 days

#9 posted 05-04-2011 12:55 AM

THAT-IS -AMAZING. I am often amazed by projects on this site. Ah the mother of invention.

-- Made in America, with American made tools....Shopsmith

View gfadvm's profile


14940 posts in 2657 days

#10 posted 05-04-2011 04:05 AM

Im very impressed and amazed. This would have occured to me but I would never figure out how to do it.Great innovation.

-- " I'll try to be nicer, if you'll try to be smarter" gfadvm

View dedalo's profile


173 posts in 2864 days

#11 posted 05-04-2011 12:01 PM

View Lenny's profile


1593 posts in 3494 days

#12 posted 05-04-2011 01:39 PM

As others before me have said, that is very impressive. You demonstrate remarkable ingenuity in creating this and your execution was great too. Well done!

-- On the eighth day God was back in His woodworking shop! Lenny, East Providence, RI

View noise_expert's profile


10 posts in 2575 days

#13 posted 05-04-2011 02:24 PM

About 10 years ago I had to design a similar ‘Y’ piece for a silencer to suit a V16 50 litre diesel engine, so am aware of some of the dificulties involved. But, wood looks a damned sight better than brushed stainless steel!

Anyway, a great looking solution to an interesting problem.

View JasonWagner's profile


527 posts in 3146 days

#14 posted 05-06-2011 01:50 AM

Totally awesome!

-- some day I hope to have enough clamps to need a clamp cart!

View Loucarb's profile


2388 posts in 3412 days

#15 posted 05-06-2011 01:58 AM

Great solution & execution. Very well done.

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