LumberJocks

Dewalt Shop Vac with Cyclone Separator Cart Caddy

  • Advertise with us
Project by Marv88 posted 12-06-2021 02:52 PM 923 views 3 times favorited 18 comments Add to Favorites Watch

My latest shop Vac/cyclone cart with some changes/improvements over the first couple seen here…

https://www.lumberjocks.com/projects/149634

https://www.lumberjocks.com/projects/331193

This time I am using the Dewalt dual stage quiet vacuum and Dewalt Cyclone separator with drum (see my review on those here https://www.lumberjocks.com/reviews/12265 )

The cabinet is built from 18mm Baltic Birch plywood and the hose holders are made from HDPE plastic.

The features include:
Folding shelf (with holes and a slot for router bit/ jigsaw blade etc clearance) so I don’t have to set the tool being using on my bench just asking to be knocked on the ground

Hose storage hanger hook doubles as a sander hanger so I don’t have to wait for the sander to wind down

Shop made plastic hose holders to keep the hose tidy yet easy to remove length needed

Fold down arm to raise hose above work when needed

Tool activated auto switch that delays turn on of vacuum to prevent circuit overload and delays turn off of vacuum to clear the hose

Vacuum speed control reduces suction when sanding so sander doesn’t get sucked to workpiece causing erratic action

Vacuum muffler/diffuser to quiet it a little more and keep the exhaust from blowing dust all over

Vacuum accessory storage pouch doubles as cord storage

Total lock swivel casters make it easily mobile yet park securely in place when needed

-- "Post count on a forum does not denote level of knowldege, skill nor experience"





18 comments so far

View Marv88's profile

Marv88

160 posts in 3241 days


#1 posted 12-06-2021 02:56 PM

Locking shelf brackets

-- "Post count on a forum does not denote level of knowldege, skill nor experience"

View Marv88's profile

Marv88

160 posts in 3241 days


#2 posted 12-06-2021 02:58 PM

Shop made HDPE hose holders

-- "Post count on a forum does not denote level of knowldege, skill nor experience"

View Marv88's profile

Marv88

160 posts in 3241 days


#3 posted 12-06-2021 03:01 PM

Vacuum speed control, hose hanger/sander hanger, auto switch

-- "Post count on a forum does not denote level of knowldege, skill nor experience"

View Marv88's profile

Marv88

160 posts in 3241 days


#4 posted 12-06-2021 03:03 PM

Polyurethane total lock swivel casters

-- "Post count on a forum does not denote level of knowldege, skill nor experience"

View Marv88's profile

Marv88

160 posts in 3241 days


#5 posted 12-06-2021 03:05 PM

Separator drum with wheels removed sits in tray for easy emptying

-- "Post count on a forum does not denote level of knowldege, skill nor experience"

View Marv88's profile

Marv88

160 posts in 3241 days


#6 posted 12-06-2021 03:08 PM

Hose arm and foldaway shelf/tray

-- "Post count on a forum does not denote level of knowldege, skill nor experience"

View Marv88's profile

Marv88

160 posts in 3241 days


#7 posted 12-06-2021 03:09 PM

Hose/sander hanger

-- "Post count on a forum does not denote level of knowldege, skill nor experience"

View Marv88's profile

Marv88

160 posts in 3241 days


#8 posted 12-06-2021 03:13 PM

Baltic birch hose adapters

-- "Post count on a forum does not denote level of knowldege, skill nor experience"

View Marv88's profile

Marv88

160 posts in 3241 days


#9 posted 12-06-2021 03:16 PM

Vacuum speed control only had a belt clip so I snapped that off and made a mounting plate from 1/8” ABS plastic

-- "Post count on a forum does not denote level of knowldege, skill nor experience"

View Marv88's profile

Marv88

160 posts in 3241 days


#10 posted 12-06-2021 03:18 PM

Shop Vac and separator model #’s

-- "Post count on a forum does not denote level of knowldege, skill nor experience"

View Marv88's profile

Marv88

160 posts in 3241 days


#11 posted 12-06-2021 03:26 PM

Muffler/diffuser, pouch for accessory and cord storage

-- "Post count on a forum does not denote level of knowldege, skill nor experience"

View Marv88's profile

Marv88

160 posts in 3241 days


#12 posted 12-06-2021 03:30 PM

Today I am making a cord to Velcro strap directly to the hose. Then I am going to cut off all the power tool cords and attach new ends making a “quick change” system like the Festool

-- "Post count on a forum does not denote level of knowldege, skill nor experience"

View LittleBlackDuck's profile

LittleBlackDuck

8693 posts in 2163 days


#13 posted 12-06-2021 10:09 PM

Cool build 88... like your add-ons and innovations.

Please don’t take the following as criticism, but rather “concept discussion”.

One “question” I would raise is the size of the wheels... but, I pose this question in many other posts.
I’ve found that tall “structures”, with a high centre of gravity (COG), wreak havoc on small wheels over floor obstructions… especially when pulled around the shop using the top attached hose.
To permit the use of larger wheels without buggering up the COG even more, I have adopted an outrigger concept rather than plonk those large wheels directly underneath,

(Just a suggestion for all mobiles... its a compromise between the extra footprint vs. better stability.)

Are your hose holders 3D printed? I’ve found 3D printed hose couplers/adapters a better compromise to wood.


... Then I am going to cut off all the power tool cords and attach new ends making a “quick change” system like the Festool
- Marv88

I have toyed with the concept so will follow this with particular interest… especially the hardware (and availability in Australia) used. If you solve the separation syndrome, you’ll have a winner. Please keep us posted on the results.
Not being a sparkie, the closest I came up with were these fittings,

They “self lock” so they won’t come apart, however, no earth (unquestionable safety issue)! To compensate (if you have an ”automatic outlet” on your vac) I have plugged in a power board and attached my tools (up to 4) to that…

so whichever tool I use, I activate the shop vac… I still have to switch the hose.

-- If your first cut is too short... Take the second cut from the longer end... LBD

View Marv88's profile

Marv88

160 posts in 3241 days


#14 posted 12-06-2021 11:42 PM

Thanks Duck! I try to use stuff I have on hand for my shop fixtures and those casters were ones I already had (the only things I bought were the cord ends, shelf brackets, hose/sander hanger and 1 elbow fitting). Unlike the version above with a much smaller footprint and motor on top this one has a lower center of gravity with the motor on the bottom and has a footprint of about 18”x20” so it is pretty stable when in motion (my main reason for building it like this).

I made the hose holders from some 3/4” and 1” HDPE plastic sheet stock I had on hand using the table saw, drill press and router table (I started off with longer than needed stock and then cut it to length after machining) .

Also, the Baltic birch hose coupling reducers are only on 2 fittings that won’t be removed (I hot glued and screwed them together) however I have made others from the HDPE plastic when they need to be removed.

The cord ends fit together very snugly however if I have any issue with those I’ll probably end up getting a cable lock like this.

I didn’t have time to finish that today but Ill post pics as soon as I get a chance.


Cool build 88... like your add-ons and innovations.

Please don t take the following as criticism, but rather “concept discussion”.

One “question” I would raise is the size of the wheels... but, I pose this question in many other posts.
I ve found that tall “structures”, with a high centre of gravity (COG), wreak havoc on small wheels over floor obstructions… especially when pulled around the shop using the top attached hose.
To permit the use of larger wheels without buggering up the COG even more, I have adopted an outrigger concept rather than plonk those large wheels directly underneath,

(Just a suggestion for all mobiles... its a compromise between the extra footprint vs. better stability.)

Are your hose holders 3D printed? I ve found 3D printed hose couplers/adapters a better compromise to wood.

... Then I am going to cut off all the power tool cords and attach new ends making a “quick change” system like the Festool
- Marv88

I have toyed with the concept so will follow this with particular interest… especially the hardware (and availability in Australia) used. If you solve the separation syndrome, you ll have a winner. Please keep us posted on the results.
Not being a sparkie, the closest I came up with were these fittings,

They “self lock” so they won t come apart, however, no earth (unquestionable safety issue)! To compensate (if you have an ”automatic outlet” on your vac) I have plugged in a power board and attached my tools (up to 4) to that…

so whichever tool I use, I activate the shop vac… I still have to switch the hose.

- LittleBlackDuck


-- "Post count on a forum does not denote level of knowldege, skill nor experience"

View AJ1104's profile

AJ1104

1457 posts in 3001 days


#15 posted 12-07-2021 01:57 AM

Very slick!

-- AJ

showing 1 through 15 of 18 comments

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics

HomeRefurbers.com