2 Stage Dust Collector Mod

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Project by JL7 posted 05-20-2012 09:22 PM 10289 views 14 times favorited 13 comments Add to Favorites Watch

I blogged about this yesterday here – but made a few more improvements today.

The quick specs:

- 1.5 HP Craftsman DC
- PSI Pleated Filter – easy bolt on
- Oneida Super Dust Deputy
- PSI heavy duty 5” and 6” flex tubing
- HF remote switch
- Free cardboard drum from work (30 gallon I think) Seems to withstand the pressure so far…..

Removed the motor and blower and mounted on the wall – hard mounted the cyclone underneath using standard HVAC fittings and some self tapping screws.

Built a wheeled dolly for the drum that can be raised up quickly and locked in place with a 2×4. When lowered the drum sits on 2 plywood runners so it’s stable…..added the wheels and plywood today so that’s not in the blog.

Also removed the old flimsy base from the Craftsman collector – mainly to save space, but also because I could aim the collector the way I wanrted as it was – plus I wanted to raise it up to minimize the flex runs. So built a new base out of MDF and old cedar post scraps.

This sucker (pun intended) really works great – I know for sure the performance using the miter saw is better than before. But, I kind of miss the sound of small wood bits crashing through the impeller….....NOT..

Just not sure why I waited so long to do this?

And I hung the mini version off the back of the shop vac – works amazing…....really.

Thanks for looking.

-- Jeff .... Minnesota, USA

13 comments so far

View BenR's profile


341 posts in 3709 days

#1 posted 05-20-2012 09:50 PM

I have a 1.5hp DC too, and this is exactly what I need to do. I will be adding the HEPA filters to the DC and shop vac, along with the cyclones like you have. I favored yours so I can refer back to it. Thanks for sharing your ideas and work. Looks like a great system!

-- Ben in Va

View fernandoindia's profile


1081 posts in 4024 days

#2 posted 05-20-2012 10:19 PM

Hi again Jeff,

yesterday I did notice the metal band closing mechanism, but I didn´t pay attention to the cardboard drum. Is that drum disposable? I hate emptying the drum. AN absolute mess. I tried to put a disposable garbage bag inside the drum, but the turbine sucks the bag in. Still need to work out that.

Nice dolly skate. The mini vac looks like R2D2 droid. :)

-- Back home. Fernando

View JL7's profile


8786 posts in 4046 days

#3 posted 05-20-2012 10:28 PM

Hey Nikki – good like on your build – you won’t regret it! Thanks for the comments!

Fernando – I suppose the drum could be disposable, but most likely not. I am hoping to keep on eye on it and empty it when it’s half full…..we’ll see how that works out…..I am waiting for the day that someone invents the “dustless” emptying system…........

I do know that changing the bag on the old system was a real pain so hoping this is better – got plenty of dust masks on hand :)

Appreciate the comments!

-- Jeff .... Minnesota, USA

View Gerry's profile


264 posts in 4322 days

#4 posted 05-20-2012 11:03 PM

Hi Jeff,

Good looking build and an inspiration to those of us with dreams of a better 2 stage dust system. I built a 2 stage dust collection system using the Thein baffle system, combining the HF 2HP dust collector with a baffled 30gallon metal trash can. I am equally happy with the results.

For FernandoIndia: If you can find some 45 gallon plastic bags( Home Depot), I have had success in dumping my 30 gallon metal dust can into them, and then discarding the whole mess. The method i use is to cover the opened can with the bag, and slowly invert it to allow the dust to flow into the bag. Then I tie it and discard it. Hope this is of help!

-- -Gerry, Hereford, AZ ” A really good woodworker knows how the hide his / her mistakes.”

View Dave's profile


11435 posts in 3921 days

#5 posted 05-21-2012 12:49 AM

She is a beauty Jeff. Nice and neat. She should serve you well.
Well Done!

-- Superdav "No matter where you go - there you are."

View Roger's profile


21054 posts in 3885 days

#6 posted 05-21-2012 02:30 AM

that should really suk

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. [email protected]

View fernandoindia's profile


1081 posts in 4024 days

#7 posted 05-21-2012 04:06 AM

“dustless” emptying system mmmhhhhmmmm

I´ll tell you, sometimes I prefer the shovel and broom dance, just to delay the dust emptying headache.

Thank you Gerry.Sounds good. I´ll try to get a big big plastic bag.

-- Back home. Fernando

View b2rtch's profile


4921 posts in 4129 days

#8 posted 05-21-2012 03:54 PM

Do you have reference for this : HF remote switch?
Here is what I did with my dust collector:
Soon I shall move it outside.

-- Bert

View WoodArtbyJR's profile


428 posts in 4046 days

#9 posted 05-21-2012 04:20 PM

Jeff, the cardboard drum won’t be a problem as that’s what comes with the larger Onieda systems. SWEET system. The remote is a MUST. Nice addition with the view window on the drum top. I have to tap mine to see how full. I think I see a revision in mine coming REAL soon. Thanks for posting.


-- Jim Roberts, Port Orchard Washington

View JL7's profile


8786 posts in 4046 days

#10 posted 05-21-2012 05:08 PM

Hey Gerry – thanks for the tip on jumbo bags – I need to check this out before it’s too late and the bin is full…..we all know how that story ends…..

Dave and Roger – appreciate the comments!

Fernando – feel free to post pictures of your shovel and broom dance…...I’m sure everyone would enjoy that!

Bert – I believe that Harbor Freight discontinued the remote switch – too bad, because it was one of those few and far between products they sell that really works good and was about half the price of the Long Ranger….Your HF mod looks really great – pretty straight forward and effective.

Jim – nice to hear from you – thanks for the comments. Glad to hear that others are using the cardboard…...there is no question when you switch the unit on, things tightened right up…..

Appreciate everyone’s comments!

-- Jeff .... Minnesota, USA

View b2rtch's profile


4921 posts in 4129 days

#11 posted 05-21-2012 05:20 PM

JL7, thanks and it works very well for me.

-- Bert

View CrazeeTxn's profile


154 posts in 3031 days

#12 posted 01-24-2013 09:10 PM

Jeff – New to these parts so be gentle :)

I’ve been using a DD on my shop vac for years and love it. Just recently scored a CL find on a Jet 1 1/2 HP DC. I want to get it running, but know I need a good filter and separator first. I mulled over building a Thien or buying this super dd. I think I’m in the mood to by and get it running.

How are you still liking yours? I thought about running like you did the 6” from from the DD to the d/c, then maybe use the 4” y to my tools. Eventually I’ll hook it up like you have, but for now, I just wanna get this sucker going.

Thanks for the inputs…


View JL7's profile


8786 posts in 4046 days

#13 posted 01-24-2013 09:39 PM

Hey Troy…...still lovin’ it…....I have probably emptied the barrel a dozen or more times, and there is only a small handful of dust in the collector bag. I can’t tell you how much easier it is to empty the barrel over the bag. It stays effienct and works like a gem.

That being said…....there are a bunch of Thein separators out there for less money, and I wouldn’t hesitate giving one of those a try…....good luck on your build!

-- Jeff .... Minnesota, USA

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