Thien Baffle, Version 1

  • Advertise with us
Project by Holbs posted 03-09-2014 05:41 AM 8296 views 15 times favorited 7 comments Add to Favorites Watch

My first attempt at a Thien Baffle. The stats:
- 16” high top hat chamber made out of 1/2” MDF.
- 55 gallon drum with 99cent 3/4” pipe insulation as sealing medium (hay… it works!).
- 6” short piece of spiral pipe squashed with my foot to become 8.5” x 4” oval at the inlet.
- 1/16” lexan x 16” high x 60” length (pretty sure it was 60”) sitting in a 1/8” deep groove (went through 2 bits for this).
- 1/8” hardboard sitting on top of the center baffle with the 1/2” MDF underneath recessed 1” away from rim.
- wanted to see what would happen if i did a 45 degree bevel at the bottom part of the lexan so that debris will not accumulate at bottom of the lexan. it works.
- all circular routing was done with the MicroFence and circular jig. What a life saver! Will have to do a “Review” on this product soon.
- for some reason, my Grizzly has a 6” inlet at the blower instead of 7” like everyone else’s in the world. instead of buying $50+ for a 10’ length of flex 6” hose, using HVAC 6” 26gauge was much much cheaper. $20?
- i cut a 14” hole on top of the baffle and a cover plate for future: possibly installing 6” bellmouth, cleaning, changing height for fine tuning, etc.
- the arc cut is wrong in these pictures except for the final. i cut the start of the arc TOO close to the inlet… and the end of the arc TOO far away from the inlet… it’s suppose to be the other way around. I had to redo the baffle plate.
- the blue barrel is raised so the inlet is same height as my 2” x 12” board that goes around my shop (which i used to hide my shop remodel electrical runs). this gives me future ‘space’ to find a way to lower the barrel to empty and this will be where my main runs of 6” will go.
- did a test run and things turned out aok. lexan didnt flex at all under vacuum, some planer debris i had laying around all fell thru the arc cut (looks to be 100%). i’m unsure of the fine dust collection to the grizzly DC itself as i have to fine tune the outlet height still.

things i have learned from this project:
1.) never again use MDF for major projects. This was the first time cutting MDF. I learned REALLY fast to cut outside of the work shop.
2.) MDF dulls blades and router bits fast. If i have to dabble with MDF, i’ll but cheap bits and blades that are disposable afterwards.
3.) i’m terrible at precision cuts and making things square. i think i rush and do not double check.

-- The Carpenter Bee is derived from the Ancient Greek word wood-cutter "xylokopos/ξυλοκὀπος"

7 comments so far

View Greg D's profile

Greg D

238 posts in 3282 days

#1 posted 03-09-2014 06:21 AM

Nice work, I need to make myself one!

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

View squaretree's profile


160 posts in 2902 days

#2 posted 03-09-2014 01:32 PM

My grizzly has a 5 inch inlet. Still looking for some flex hose for it myself…..

-- if you can't find me, just follow the extension cord

View Holbs's profile


2388 posts in 3360 days

#3 posted 03-09-2014 03:00 PM

i “might” redo the inlet to grizzly HVAC to add 3 more adjustable elbows to give a more smooth bending action than what i have now.

-- The Carpenter Bee is derived from the Ancient Greek word wood-cutter "xylokopos/ξυλοκὀπος"

View blackcherry's profile


3349 posts in 5153 days

#4 posted 03-09-2014 07:14 PM

Hope this unit works out for you mine has been one of the best project Ive made for my shop. Also I could not agree with you more about MDF, really have no need for that mess!

View timbertailor's profile


1594 posts in 2754 days

#5 posted 09-19-2014 04:20 PM

I really like the dual outlet system and your clear Thien Cyclone. I Just stuffed mine in a trash can.

My only suggestion is to invest in some Wynn Evironmental Filters ASAP. Not good for your health to be blowing the finer stuff under 5 microns all over the shop.

-- Brad, Texas,

View Holbs's profile


2388 posts in 3360 days

#6 posted 09-19-2014 11:13 PM

this has worked flawlessly. i probably only have a couple inches in the bottom of my dual bags where as i would of emptied both once or 2x’s by now. and emptying the blue barrel is a breeze: lower the platform, scoot out, remove 55 gallon trash liner bag, put in new one, re-install barrel.
i still have yet to 100% seal the “chimney” pipe or get a bell mouth.
oh… i have since added 45-45 for every bend into the impeller instead of using 90’s.

-- The Carpenter Bee is derived from the Ancient Greek word wood-cutter "xylokopos/ξυλοκὀπος"

View Holbs's profile


2388 posts in 3360 days

#7 posted 09-19-2014 11:19 PM

odd. i thought i made a short video of the baffle in action. i’ll repost here:

Operational Thein Baffle
oops… looks like using old embedded code from YouTube is… broken again on LJ’s. grrr…
here is the link:

-- The Carpenter Bee is derived from the Ancient Greek word wood-cutter "xylokopos/ξυλοκὀπος"

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