I Am Baffled, Or Rather I Would Like To Be

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Forum topic by Kazooman posted 03-22-2017 01:34 AM 849 views 0 times favorited 5 replies Add to Favorites Watch
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1237 posts in 2152 days

03-22-2017 01:34 AM

I have a pretty decent dust collector setup with ducting to most of my machinery. The lone wolf is attached to my table saw. I have a smaller dust collector that I bought way back when and it is now dedicated to the saw.

It is one of the older model Delta dust collectors that has a 35 gallon fiber barrel with the motor and impeller mounted on the top. Here is a picture for those who may not be familiar with this (admitted lousy) design. Also a picture of the underside of the lid showing the inlet for the collection hose and the connection for the impeller.

The collector moves enough air to handle the cabinet and over-arm collection system for my SawStop PCS, but there remains a problem. Emptying the collection bag is a major league PITA and most of what is collected ends up in the bag. So, I have this genius idea to incorporate a baffle inside the drum with the hope that it will help shunt more of the waste to the drum. I realize I would need to empty the drum more often, but that beats emptying the bag.

Here are the specific challenges and the questions they raise.

The impeller is mounted off center. How will that impact any baffle design?

The current inlet is flush with the lid, but the inlet to the impeller extends a good four inches into the drum. If I install a 90 degree elbow how far into the drum does it need to go? Does it need to be lower that the inlet to the impeller?

How far below the input elbow and the output tube does the “baffle plate” (I do not know what to actually call it) need to be mounted?

Should the elbow be pointed in the same direction as the rotation of the impeller to get maximum benefit? Or does the the 4” extension of the outlet into the drum negate any issues with air flow direction?

Has anyone else ever made this modification? Not that I have been able to find through searching.

I can try this really cheap for the price of an elbow, some all-thread and nuts, and a piece of scrap plywood. I can even repair any mods made to the existing collector.

So…... any advice would be appreciated.

5 replies so far

View jbay's profile


2865 posts in 1099 days

#1 posted 03-22-2017 01:47 AM

I used to have one of these but it’s been a long time. I was looking through the replacement parts because I thought mine used to have an inside filter, but I guess not,
though it does look like there is a dust deflector (#23)
Does yours have this, or a place for this?

View pontic's profile


643 posts in 808 days

#2 posted 03-22-2017 01:51 AM

A 90deg. turn in airflow will severely reduce the efficiency of the suction produced. It will also cause eddy currents thet will trap chips and cause buildup in the elbow and thus a stoppage. A 45deg would be better. If you don’t want to make a deflector then just aim the 45 pipe to the outside wall somewhat. Hope this helps.

-- Illigitimii non carburundum sum

View Lazyman's profile


2617 posts in 1587 days

#3 posted 03-22-2017 02:20 AM

Here is a Youtube video by Marius Hornberger that shows a design that should work well for your vac. His may be a little over engineered but it looks like it works pretty well. Just havng the inlet on the side and injecting the air so it swirls will help significantly.

-- Nathan, TX -- Hire the lazy man. He may not do as much work but that's because he will find a better way.

View Kazooman's profile


1237 posts in 2152 days

#4 posted 03-22-2017 12:09 PM

Thanks! Three great replies. First, my collector does not have the dust deflector. I would bet that they added it in later models to address the issue I have been facing. Good point on the 45 vs 90 elbow. I want to retain as much airflow as possible. That is quite a setup in the video. A real work of art.

I think that the first thing I will try is installing a homemade dust deflector to get the airflow swirling. A “carefully” shaped piece of sheet metal should do the trick. The concern I have is that while the inlet is right at the edge of the drum and I can get the air rotating, the outlet is not in the center. I will never achieve the vortex of a proper cyclone. Just getting some added collection into the barrel will be a real help. As it is I need to empty the bag many times before enough waste collects in the barrel to bother with. Emptying that bag is a real messy ordeal.

I may still need to install a plate so that what waste does fall into the drum is out of the airflow.

View Kazooman's profile


1237 posts in 2152 days

#5 posted 03-22-2017 09:50 PM

Hey jbay:

I did a bit more research and found a pdf of a Delta manual for the collector with the dust deflector. The pictures there confirm my thoughts on the proper direction for the deflector. The image on the ereplacementparts drawing constitute an optical illusion and you could convince yourself that either direction was intended.

The assembly instructions in the Delta manual specify the depth that the deflector should extend down into the drum. They actually provide instructions that this distance can be adjusted by bending the deflector (why didn’t I think of that???).

At any rate, I can now introduce this upgrade into my old dust collector. I think I will pass on the ereplacementparts piece of bent sheet metal that commands a price of $85.13!!! I probably have a piece of sheet metal stock that will do the trick.

Thanks again for pointing this change in the collector out to me.

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