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Thien baffle build question...

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Forum topic by Jim Dawson posted 07-09-2016 01:05 PM 653 views 0 times favorited 13 replies Add to Favorites Watch
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Jim Dawson

48 posts in 292 days


07-09-2016 01:05 PM

I’m going to attempt to build a Thien baffle but I’ve already run into a question – where can I buy the Lexan and what thickness do I buy? I’ve seen many thicknesses online and really expensive large sheets. Do any of the big box stores carry something suitable?

Thanks,
Jim


13 replies so far

View HorizontalMike's profile

HorizontalMike

7143 posts in 2374 days


#1 posted 07-09-2016 01:28 PM

FWIW, I built my trashcan top Thien using 3/4”plywood, 1/4” hard board, some all-thread, and a couple of 90* 4” couplings.

http://www.horizontalheavens.com/Thien%20Dust%20Separator.htm

If it didn’t work so well, and it does, I would have replaced it with an artsy fartsy unit… ;-)

-- HorizontalMike -- "Woodpeckers understand..."

View Holbs's profile

Holbs

1371 posts in 1489 days


#2 posted 07-09-2016 02:51 PM

I bought my Lexan locally at a plastic shop, the kind of place that sells plastic for business signs and such.
http://www.silverstateplastics.biz/
went 1/16” lexan x 16” high x 60” length for $20 or so.

-- Yes, my profile picture is of a Carpenter Bee! The name is derived from the Ancient Greek "wood-cutter"

View johnstoneb's profile

johnstoneb

2143 posts in 1633 days


#3 posted 07-09-2016 03:27 PM

I just used the trashcan lid separator Woodcraft sell added an inlet elbow to direct the flow toward the outside of the can and hung a baffle below the elbow on all-thread. Works great.
Mine looks a lot like Horizontal Mike’s with out the cutout on the elbow. You definitely don’t need all that artsy fartsy stuff.

-- Bruce, Boise, ID

View Rentvent's profile

Rentvent

148 posts in 309 days


#4 posted 07-09-2016 07:54 PM

I made one out of a cardboard drum:

Here’s before I added in the bottom circle with the slot:

the blue ring is the cut-out lid of the plastic drum that it sits on

The other half of the cardboard drum in the background is to hold the donaldson\wynn filter.

The black bellmouth fitting on the outlet pipe in the center is a subwoofer port

View joey502's profile

joey502

487 posts in 978 days


#5 posted 07-09-2016 08:51 PM

The bix stores around me sell polycarbonate . Most mom and pop hardware stores have it on hand to cut the size you need.

The plastic will cut nicely on a bandsaw if you find an oversized piece.

Lexan is a brand name of polycarbonate. If you search or ask for polycarbonate instead of the name brand you may have more luck sourcing what you need.

View JIMMIEM's profile

JIMMIEM

39 posts in 302 days


#6 posted 07-09-2016 08:56 PM

Trash can and 1/2” plywood for the baffle. Threaded rods. Plastic parts from Grizzly.

View Woodchuck2010's profile

Woodchuck2010

504 posts in 318 days


#7 posted 07-10-2016 01:13 AM



FWIW, I built my trashcan top Thien using 3/4”plywood, 1/4” hard board, some all-thread, and a couple of 90* 4” couplings.

http://www.horizontalheavens.com/Thien%20Dust%20Separator.htm

If it didn t work so well, and it does, I would have replaced it with an artsy fartsy unit… ;-)

- HorizontalMike

Really like your shop!

-- Chuck, Michigan,

View Jim Dawson's profile

Jim Dawson

48 posts in 292 days


#8 posted 07-10-2016 01:46 AM

Thanks for all the tips. I’ll start on it soon.

View curliejones's profile

curliejones

154 posts in 1726 days


#9 posted 07-26-2016 11:49 AM

I used acrylic sheet from an old light fixture. I had plenty on hand and it works just fine. It is opaque and has the advantage of letting you see (somewhat) that cyclonic effect is there without mesmerizing you for hours on end and no work gets done LOL.!

http://lumberjocks.com/projects/252418

-- Like Guy Clark sez - "Sometimes I use my head, Sometimes I get a bigger hammer"

View Notw's profile

Notw

467 posts in 1213 days


#10 posted 07-26-2016 03:09 PM

I used metal flashing for mine, works great

View Mark's profile

Mark

819 posts in 1435 days


#11 posted 07-26-2016 03:54 PM

- HorizontalMike….Any thoughts how your top hat might work with a DW735? Sweeping’ the floor all the time is making’ me tired. Thanks.
PS not trying to hack Jim’s thread.

-- Mark

View toolie's profile

toolie

2022 posts in 2088 days


#12 posted 07-27-2016 12:44 PM

Put the baffle in the dust collector and save space( no separator) while limiting the dust in the filter.

-- there's a solution to every problem.......you just have to be willing to find it.

View WoodES's profile

WoodES

36 posts in 1151 days


#13 posted 07-28-2016 03:54 AM

I found the best sheets at Lowes. I forget the brand but was easy to flex into the circular shape. The sheet I found in the local plastic distributers scrap pile kept breaking. I only used a thickness of about 1/8” and it has worked very well.

Good luck.

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