Added a second stage to my dust collection system.

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Blog entry by 58j35bonanza posted 03-08-2011 08:50 AM 8900 reads 0 times favorited 2 comments Add to Favorites Watch

I have an older dust collector that I purchased used a few years ago, I think it is a Delta and was painted green. You can see Delta blue where the paint has come off.

I had been thinking on how to build a second stage to add onto my system, and had been reading blogs and watching u-tube videos. I even had been checking out trash cans to make the one with 2 pvc elbows but wasn’t in any rush to make one. That was until, I washed the lower and upper. I know your not suppose to wash them but they really looked bad.

Well, when I put them back on and turned on my system it started to fill the room with dust, you could actually see the dust blowing out of the poors in the upper bag.

When the dust settled….I knew it was time to get busy and do something.

I was at a customers and we were out in his plant as he was showing me around, he asked me if I wanted any barrels. My eyes got big as I saw these nice plastic barrels with lids stacked to the ceiling. He said that they threw them away as his supplier didn’t want them back. Well, when I left, a barrel went with me. I felt like a kid with a new toy.

First I got some schedule 20 plastic pipe and cut it so it would wrap around the barrel. I also cut a hole in the barrel to match the pipe. When I attached it to the barrel I made sure it was level, so that it wouldn’t direct the air flow up or down as it went around the barrel. I used some 7 minute epoxy to attach the pipe to the barrel.

I then went over it with some good old J.B. Weld. I also made the air flow go counter clockwise (like a tornado spins) not sure if it would make a difference or not. I then sanded the area smooth and used some primer and black spray paint for plastic that I had.
I also took the 2 cloth filters that were on the system and doubled them up to cut down on any dust that might come out.
I can’t tell you how well this works! No dust has gotten into the plastic bag that I got at woodcraft to replace the lower bag. I do intend to either get a new upper bag or the paper filter to replace the upper bag.

What a week! I now have a 2 stage system and I only had to purchase the lower plastic bag.

-- Chuck

2 comments so far

View Ocelot's profile


3412 posts in 3884 days

#1 posted 03-10-2011 06:22 PM

Cool project!

I might try this sometime. Does it seem to decrease the air flow at all?


-- I intended to be a woodworker, but turned into a tool and lumber collector.

View 58j35bonanza's profile


395 posts in 3938 days

#2 posted 03-11-2011 02:24 AM


I thought that it might decrease the air flow, but so far so good.

I think without all the dust getting up into the top bag and clogging it up, the airflow actually seems better than before I added the second stage.

Since I first posted this, I have also added some filter material so that no dust gets through to the bags. It seems to be working really well, and I have noticed that a thin layer of dust is not all over everything in my shop.

I think everyone should have one of these.

-- Chuck

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