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In my last post on this subject, I built a prototype dust separator and tried it out. It worked pretty well, but it lost suction when the bottom bucket was about half full. In that post, I told you about how I expected to do a phase two of the construction. Well, I finally did it!
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Parts List:
- 1 – 32-gallon trash can with a lid
- 1 – 6-inch section of 1-1/4 inch PVC I already had
- 1 – Shop-Vac cartridge filter
- Caulk and caulk gun
- The dust separator from Phase 1
Tools:
- Hack saw
- Rotary tool
- Sandpaper to clean up cut edges
Separator modifications
I removed the separator portion from the other 5-gallon bucket and traced around it on the lid of a 32-gallon trash can. I used my rotary tool to cut the hole a little on the inside of the traced line. You can always cut a hole bigger…you can’t cut it smaller. After a few rounds of testing, trimming, and re-fitting, I got the separator to fit.
I ran a bead of caulk all the way around the inside of the lid in order to create a better seal between the lid and the can. I let it cure so it can be a reusable seal.
I also ran a bead around where the separator passes through the lid, but removed it after the hose clogged in testing and the lid collapsed in. Having a little bit of space for suction in case of a malfuction is a
While the caulk cured, I took the opportunity to make sure the suction is directed in from the side opposite the intake. This further reduces the incidence of sawdust getting passed through into the shop vac. I did this by cutting a 1-1/2 inch tall section off half of a length of pipe. I inserted it into the suction intake and made sure it was flush with the bottom of the stand-offs, then twisted it so the opening is pointing exactly away from the intake.
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Shop-Vac changes
I added a cartridge filter to the shop vac in place of the old paper filter. This makes sure the air exhaust from the shop vac is clean.
Testing results
It works great! Well under a quarter cup of fine sawdust made it into the shop vac after sweeping up well over 5 gallons worth of sawdust and plane shavings. I still have to take it slow with chisel and plane shavings, but I expected that. By hooking it up to an automatic vac plug, I can have it come on when I turn on the tool and shut off just after the tool turns off.
All in all, I’m very happy with the results. It builds up some static that needs addressing, but I’ll get to that. I put about 3 hours worth of work and less than $75 into building this – much cheaper than any of the commercial options. I haven’t decided whether to go ahead on to phase 3 of making a cart or not. With it in one place and the hose being long enough to reach both tools I would use it with, the extra effort may not be necessary.
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