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It's Alive - 2 stage cyclone dust collector

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Project by EarlS posted 12-05-2019 11:57 PM 1351 views 5 times favorited 23 comments Add to Favorites Watch

One of the biggest complaints I had with my previous shop was the Laguna C-Flux dust collector. It had lots of bells and whistles and was really expensive but was lacking in the basic necessities such as air flow and vacuum. With that in mind, I resolved to install a better dust collector for the new shop.

I knew I wanted a 2-stage system; a cyclone followed with a 0.5 micron filter. It had to provide at least 800 cfm and 11” of vacuum. Oneida’s Mini-gorilla ($1350) looked like it might just meet the requirements while the V-System 300 would meet the requirements but was $2500. The Clear-Vue CV-1800 also looked promising but was $2100. After a lot of deliberation, I decided I could build one for considerably less cost and spend the money I saved elsewhere.

I was able to find a used Delta 50-850 2 HP dust collector for $250 that I rewired to 220V. I also bought the Super Dust Deputy 6” XL ($250) since the fan inlet and outlet were also 6”. Rather than use 6” SCH40 PVC since it is really heavy, I bought 6”x10’ flex hose ($50). With the larger diameter the pressure loss from the hose didn’t concern me nearly as much as if it had been 4”. A 0.5 micron pleated filter was also $200. The dust collection barrel was $15 on Craigslist and has a band to tightly seal the lid.

Some 2×4’s and a 4×8 sheet of inexpensive plywood make up the frame. The fan motor is bolted to the frame and the frame is screwed into the wall. Screwing the frame to the wall ensures the whole contraption won’t tip over and also reduces vibration that would come from an unsecured setup. A hole for the cyclone discharge was cut into the plywood with a scroll saw. Bolt holes for the flange blots allow the cyclone to be securely connected to a flange with a short section of hose that dumps into the dust barrel. By running the bolts through the plywood, the bottom of the cyclone is secure. Caulk sealed up any gaps.

The fine dust will collect on the pleated filter. Having a collection bucket or bag under the filter was pointless since the air flow is so turbulent that the dust will just get pulled back onto the filter. The purpose of the collection box with the plexiglass front is to provide good access when the pleated filter is cleaned out. I can get the shop vac wand into the interior of the pleated filter to vacuum the dust off.

Rather than use PVC wyes, I made a distribution header with a clear front so I can see the dust and chips as they are pulled into the cyclone. I’m an engineer so being able to see how much material is being collected is kind of cool too. Rather than use 4” flex hose for the vertical runs, I used thin wall PVC. The table saw has a 4” PVC line to it and the Sharkguard blade guard also has a 4” line running to it.

This set up is far superior to what the Laguna was able to do. I don’t have to worry about chips building up in the table saw. With the higher flow and improved vacuum, the Sharkguard pulls off the chips and dust coming off the blade. The “other tools” line has 4” flex hose on it so I can hook it to the jointer or router. For planing, I use a garbage can collector to capture most of the chips since the DW735 has a small chip blower. In all of these cases, the dust collection is far superior to the Laguna set up.

I splurge with some of the $$ I saved and bought the I-Vac system that allows the dust collector to start automatically when the machine is started. It is really nice not to have to start and stop the dust collector. I might also get the I-Vac blast gates since I keep forgetting to open/close them as I switch between equipment.

The biggest downside is the size of the DC frame (2’x4’x8’). I suppose I could have used the 5” SDD and likely would have gotten similar performance. Did I save any money? I probably spent right around $1000 by the time I was done, so I did save some money More importantly, I learned a lot about dust collection and was able to put some of my engineering into practical use. Did I mention I also bought an anemometer and a manometer so I can measure the air flow and vacuum around my set up? Yep I’m a nerd.

-- Earl "I'm a pessamist - generally that increases the chance that things will turn out better than expected"





23 comments so far

View duckmilk's profile

duckmilk

3938 posts in 1931 days


#1 posted 12-06-2019 12:09 AM

Congrats Earl! That looks nice and tidy ya nerd ;-)

-- "Duck and Bob would be out doin some farming with funny hats on." chrisstef

View GR8HUNTER's profile

GR8HUNTER

6819 posts in 1319 days


#2 posted 12-06-2019 12:13 AM

well for a nerd you sure have built a really nice system and at half the price GREAT JOB :<))

-- Tony---- Reinholds,Pa.------ REMEMBER TO ALWAYS HAVE FUN

View anthm27's profile

anthm27

1600 posts in 1717 days


#3 posted 12-06-2019 12:13 AM

Brilliant set up, Nice work.
Imagine how many Mallets that could be made from the dust that is going to be collected?
Great job.
Regards
Anthony

-- Hand Skills provide freedom.

View 489tad's profile

489tad

3731 posts in 3618 days


#4 posted 12-06-2019 12:26 AM

That’s a nice system.

-- Dan, Naperville IL, I.G.N.

View pottz's profile

pottz

7696 posts in 1591 days


#5 posted 12-06-2019 12:38 AM

damn earl what kind of frankeduststein collector have you created ! better run bud the villagers are coming-lol.

-- sawdust the bigger the pile the bigger my smile-larry,so cal.

View GR8HUNTER's profile

GR8HUNTER

6819 posts in 1319 days


#6 posted 12-06-2019 12:51 AM



damn earl what kind of frankeduststein collector have you created ! better run bud the villagers are coming-lol.

- pottz


I like that :<)))

-- Tony---- Reinholds,Pa.------ REMEMBER TO ALWAYS HAVE FUN

View oldrivers's profile

oldrivers

1959 posts in 2173 days


#7 posted 12-06-2019 01:20 AM

That is really a nice collection system. Congratulations on a job well done.

-- Soli Deo gloria!

View James E McIntyre's profile

James E McIntyre

569 posts in 1899 days


#8 posted 12-06-2019 03:32 AM

Fine job. When can you stop by and help me install one here. (:~)

The Delta system looks great.

-- James E McIntyre

View Scott Landry's profile

Scott Landry

198 posts in 2077 days


#9 posted 12-06-2019 04:57 AM

Can’t beat 2 stage. And the blue chemical drum is the best. I see that you have some clearance above the filter so that you can lift it up higher provided it will clear the garage door rails. If so I would mount it as high as you can then you can maybe get another tool under there. I did it and was able to get my band saw under the motor. You will love the 2 stage. Here is a link to my dust collector. https://youtu.be/SkIFPjJOQNU

-- Every project is an opportunity to acquire new tools and any solution that requires buying a new tool is the correct one.

View Rick  Dennington's profile

Rick Dennington

6789 posts in 3801 days


#10 posted 12-06-2019 05:57 AM

Dang! That’s a heck of a set you have there, Earl…..Looks like it’ll do the job with no problem….I too have an old Delta 50-850 that I bought new back around 1990 (?). I use the Wynn filter and clear h.d. plastic bag…..I have it in a room that I built specifically for the dust collector and air compressor to “knock down” the noise…..Never had a problem with the old Delta ( knock on wood)....Your setup is sweet, and will get the job done, I’m sure…..!

-- " There's a better way.....find it"...... Thomas Edison.

View sawdustjeff's profile

sawdustjeff

24 posts in 2148 days


#11 posted 12-06-2019 03:08 PM

Wow!! I’m in the process of doing the same thing!
I’m about 50% finished with the PVC piping, got delivery on the Series 35 filter (God bless Wynn, they were a huge help).
Woodcraft has had the Dust Deputy on backorder for weeks. I think it’s about time to cancel that order and talk to Oneida directly.
I was beginning to lose confidence that this was going to work but not anymore.
Thanks Earl, you just made my day!!

View bigblockyeti's profile

bigblockyeti

6184 posts in 2327 days


#12 posted 12-06-2019 03:53 PM

I bought a use Grizzly G0440 and had it installed but not completely plumbed in my last shop. I also have a couple Delta 50-181 1100CFM blowers I’ve been dragging around for a while that I was considering doing something with before I bought the Grizzly. Now I have a three car garage smaller than my former 2 car garage (with a lower ceiling) and no separate shop, so everything is crammed in there complete disaster style. Looks like you’ve gotten everything set up quite well and that dust collector looks like quite the project!

-- "Lack of effort will result in failure with amazing predictability" - Me

View EarlS's profile

EarlS

3427 posts in 2955 days


#13 posted 12-06-2019 04:17 PM

Jeff – I bought mine directly from Oneida and it arrived in a couple of day.

I spent a lot of time tweaking the design as I built it, both for space, and for performance. I set up a partial system for a week and tried it out, then redesigned things based on how I was using it.

For example, the handle for the pleated filter cleaning paddle was basically inaccessible on the first design so I got rid of the legs under the filter and built the box with a window.

Initially, the filter had a clear bag under it so I could see that any dust i cleaned off the pleated filter that collected in the bag was stirred up enough that it was re-entrained in the air and re-deposited on the filter. That lead me to realize the only reason for a chamber under the filter is access for when the filter is opened to clean the pleats and remove the dust. Nothing will accumulate there unless the cyclone barrel fills up or some other failure allows a lot of material into the pleated filter. If that happens I will have to open things up and clean it out anyway.

-- Earl "I'm a pessamist - generally that increases the chance that things will turn out better than expected"

View Rick  Dennington's profile

Rick Dennington

6789 posts in 3801 days


#14 posted 12-06-2019 05:05 PM

Those old Delta 50-850 dust collectors are just like that pink rabbit advertising TimeX watches…..They just keep going, and going, and going…..Back then they were American made….Don’t even know if they still make that size…?

-- " There's a better way.....find it"...... Thomas Edison.

View EarlS's profile

EarlS

3427 posts in 2955 days


#15 posted 12-06-2019 05:09 PM

If Delta does, I doubt they are as sturdy as the old ones. It’s all cheap Chinese thin wall stamped junk.

-- Earl "I'm a pessamist - generally that increases the chance that things will turn out better than expected"

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