Dust Deputy mod

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Project by Michael posted 06-02-2014 06:21 AM 4990 views 8 times favorited 3 comments Add to Favorites Watch

Did a little vacuum modification. I think the dust deputy is great, and worth the $40. However, I found it impractical to be pushing around a big empty shop-vac and a tiny 5 gal bucket full of dust. I remember seeing a ClearView mini separator configured similar to this. I also did all the modifications so the vac could be put back into it’s original state incase I needed it to vacuum water or my ideas just plain-old didn’t work.

First things first. The rigid vacuum comes with horrible wheels. The bigger casters make it roll much better. I wish they could be another size bigger but it’s top heavy enough how it is. I just cut pieces of plywood to fit where the old wheels were and screwed the ply in. The new wheels are bolted to the plywood.

The Dust Deputy works just like advertised. I’m sure you can find a bazillion pictures of an empty vacuum and a bucket full of dust. Same here. But I have learned some stuff about it. Air speed is everything. When I am using a sander or drywall cut-out tool that hook up with a smaller hose I have a coupling with some holes drilled in it, I included a photo. I found the slowing down or decreasing the amount of air the cyclone has going through it lessens it’s effectiveness. Having about 4-6 3/8” holes seemed to make it better. Even when the sander is on a flat surface there is always air flowing. When using the roto-zip on drywall this made a big difference.

The filter is held in the box by the lid. I put some weather stripping material places I had sealing issues. The filter box is next on the list to be re-engineered. It does the job now but it’s heavy (wood is not great for everything) and makes the vac less stable on uneven surfaces. I’m thinking of ways to make it lighter and smaller. Again, the point here is to allow enough space for the filter to function not hold lots of dirt.

The other thing I tried was to configure it like the Ultimate Dust Deputy} kit they sell for the Festool vac. The big square box that the dust dumps in for that model has an option to put a plastic bag in the catch the dust. They accomplished that by an additional tube that sucked the air out from around the outside of the bag. I tried with a black garbage bag and a tube connecting the filter-box to the hose inlet. It barely worked, I think mine leaks too much air with the garbage bag to work.

Anywways, it’s no Festool vac but definitely work 10x better than stock.

-- Michael

3 comments so far

View Jim Jakosh's profile

Jim Jakosh

24787 posts in 3876 days

#1 posted 06-02-2014 11:27 AM

Nice work on your vacuum set up. I have a DD and love it, too!!

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View J Azuma's profile

J Azuma

30 posts in 2253 days

#2 posted 06-03-2014 12:29 AM

That is really a great idea that eliminates the 5 gallon bucket. Now somebody just needs to design a silencer…

-- J Azuma

View tsiawdt's profile


1 post in 2113 days

#3 posted 09-25-2014 02:10 AM

I have a stihl se122 vac its only 69 dbs it is sooo quiet

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