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Project by tyvekboy posted 05-02-2013 07:07 PM 7684 views 26 times favorited 16 comments Add to Favorites Watch
ENHANCED CYCLONE SETUP • No picture No picture No picture No picture No picture
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May 2, 2013

I had the good fortune to stumble across the cyclone end of an old commercial Delta Dust Collection system. The motor had died and it was headed for the scrap pile. I managed to get the cyclone portion of the system which was a heavier gauge of metal and more compact than the one I had. This is what i did with it.

The cyclone was approximately the same size as the one that I posted earlier. Here is a comparison photo of the two systems. That meant that I could reuse the cyclone holder that I had previously built.

I had to recut the cone supports to fit the new cyclone but other than that, the cyclone holder remained unchanged.

The only thing that I had to do is create adapters for the three openings: INPUT, OUTPUT, and DUST RECEPTACLE.


The input transition consisted of cutting and gluing THREE 3/4 inch plywood rings that fit the input pipe. The transition to the 4 inch size consisted of TWO smaller 3/4 inch plywood rings glued to the bigger plug. In the middle of the smaller ring I inserted a 4 inch plastic hose splice to which I attached a 90 degree Dust Right elbow to which I attached my flexible hose. The transition piece was secured with 4 pan head sheet metal screws and silicone caulk was applied to the inside to eliminate any air leaks.


This cyclone consists of two parts: the outer shell and an inner core. The inner core consists of a circular piece of metal with a hole in the center to which a long tube is welded that extends down into the cyclone. A directional vane welded to the outside of this tube. The impeller and motor of the original DC system was then mounded on top of this cyclone and bolted down with the 8 bolts seen here.

For my transition, I made a cover out of 3/4 inch plywood with holes that matched the bolt pattern. To the hole in the center of this plywood cover I glued a THREE 3/4 inch circles that fit snugly into the ducting seen in the picture.

Caulking was applied to the rim of the outer cyclone shell and also to the top rim of the inner cyclone core. I let the caulking cure for 24 hours before assembling this part of the setup.


The transition to the 20 gallon trash can was also created with plywood. The cover to the trash can consists of and outer and inner plywood rings with about a 1 inch space between them glued to the top of a bigger plywood disc. This fits nicely over the rim of the trash can. In the 1 inch space between the plywood rings I install some weather stripping foam to seal it.

The transition to the bottom of the cyclone uses a stack of 5 or 6 plywood rings sized to fit snugly into the opening. This stack of rings was then glued to the trash can cover.

This transition was then secured to the bottom of the cyclone with 4 pan head sheet metal screws. Caulk was applied to the inside of the cyclone to make it air tight.

After all the modifications were done, I gave the cyclone a coat of primer and fresh paint.

The new system really sucks!

If you’re as lucky as I was to make a find like this, you can use this idea to improve your dust collection system.

Hope you like this idea. Comments encouraged and welcomed.

Thanks for looking.

-- Tyvekboy -- Marietta, GA ………….. one can never be too organized

16 comments so far

View HillbillyShooter's profile


5811 posts in 3576 days

#1 posted 05-02-2013 07:53 PM

Looks good—I’m going to have to favorite this so I can really study it later. Thanks for the post.

-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington

View dtzeutschler's profile


6 posts in 3252 days

#2 posted 05-02-2013 08:44 PM

Nicely done; very professional job!

View geppetto's profile


39 posts in 4355 days

#3 posted 05-02-2013 08:59 PM

Very creative. Now that is recycling.


View Jim Jakosh's profile

Jim Jakosh

27002 posts in 4389 days

#4 posted 05-03-2013 12:08 AM

Nice 2 stage dust collectors!!!!!!!!!!...........Jim

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

View luv2learn's profile


3147 posts in 3587 days

#5 posted 05-03-2013 01:09 AM

What a find and what a great way to give it new life.

-- Lee - Northern idaho~"If the women don't find you handsome, at least they ought to find you handy"~ Red Green

View BryanatWoodstock's profile


101 posts in 3318 days

#6 posted 05-03-2013 10:47 AM

I am thinking you need to increase the hose size to the dc from 4” to 6”. The 4” is choking the air flow.

View hotrodadcox's profile


30 posts in 4226 days

#7 posted 05-03-2013 01:30 PM

Very nice design, I’ll have to re-look at mine
Thanks for sharing

-- hotrodjohn, colorado

View grumpy749's profile


228 posts in 3661 days

#8 posted 05-03-2013 02:27 PM

Ya this looks really good and you saved yourself a ton of money. I’m sure it works as good as it looks and you enjoyed the process, all positives. But the real kicker is we all received a benefit, great stuff. I use three different collectors in my shop and the latest is a two HP Laguna. It wasn’t cheep but works great. I had considered going your route but I just couldn’t lay my hands on a cyclone big enough. very nice indeed.

-- Denis in Grande Prairie. Yesterday is history, tomorrow is a mistery, but today is a gift. That is why it is called the present.....Pink !

View Greg D's profile

Greg D

238 posts in 3235 days

#9 posted 05-03-2013 03:15 PM

Lucky find! Great job!

-- Greg D, Cen. CA, "Keep it on the Level, Do it Right the First Time!"

View fstellab's profile


86 posts in 3369 days

#10 posted 05-03-2013 07:28 PM

It’s Almost a work of art, very impressive, the sawdust does not have a chance !

-Fred S in Jacksonville, FL

-- Fred Stellabotte ([email protected])

View dukeofburl's profile


13 posts in 3218 days

#11 posted 05-04-2013 12:31 AM

Great idea! I was wondering, how big of a dust collector do you need to make this work?

-- dukeofburl

View kiefer's profile


5852 posts in 3951 days

#12 posted 05-06-2013 04:33 AM

So what you are saying that the larger diameter of the cone gives better results ,at least that is the way I understand it .
Would larger duct work help even more ?

Nice rework .

-- Kiefer

View tyvekboy's profile


2138 posts in 4297 days

#13 posted 05-06-2013 04:38 PM


That would be nice to increase the hose size to the DC from 4” to 6” but when you take the splitter off at the impeller housing, you’ll see that the opening is only 4” so there is no gain.


I didn’t understand your comment. My enhancement didn’t change the diameter of the cone. In fact, both cyclone cylinders were about the same size. The only difference in the cone was that the newer cone is shorter which made the whole setup sit lower.

For others looking to add a cyclone to their dust collector:

You don’t have to wait for a find like mine. Remember, the first one was made by a friend of mine with just sheet metal. That first one worked great.

You just have to figure out how to form the cone. I’m sure you can find places on the internet that will help you with that. Then if you don’t know how to solder, you can make it like my first one with screws or pop rivets and duct tape. As long as it is air-tight you’re in business.

-- Tyvekboy -- Marietta, GA ………….. one can never be too organized

View Mauricio's profile


7168 posts in 4435 days

#14 posted 05-06-2013 04:42 PM

Pretty cool!

-- Mauricio - Woodstock, GA - "Confusion is the Womb of Learning, with utter conviction being it's Tomb" Prof. T.O. Nitsch

View Fishin's profile


5 posts in 3126 days

#15 posted 05-10-2013 04:20 PM

Very cool, I made a 2 stage also. I like yours because it takes up less space. I will take pictures and post mine on here. I really like making my own equipment and being able to fix them if they were to go bad and I love the challenge. Very good build.

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