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Just thought I would share my version of the HFDC Thien Baffle transformation. I didn't want to have my motor permanently mounted to a wall above the barrel, so I decided to attach it right to the metal lid of the barrel, which worked great. I plan on venting it outside since there is very little dust that the separator doesn't catch based on most peoples reviews.

This design is based off of Phil Thien and his research and work in creating a design for a cyclone baffle. You can find more information here:
http://www.cgallery.com/jpthien/cy.htm

I used the pipe template making software at:
http://www.harderwoods.com/pipe.html
to create the cutting templates for both cutting the pipe and the side inlet. The pipe was attached to the barrel using 5 minute epoxy and turned out to be very strong and was an original concern of mine.

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Looks like a great implementation of Phil's design. Where did you get the barrel?

-Russ
 

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Nice. How big is the motor (hp and voltage) and where did you get it?
 

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Russ- I found the barrel at a local packaging company for $10. You can order them online by doing a search for "fiber drum" on google.

Alex- I bought the motor for $139 on sale at Harbor Freight. If you do a search on LJ's or even google for HFDC, you'll see a lot of people who have had very good experiences with these DC's. It runs on 110v and they claim that it's a 2 HP motor, but most people seem to agree that it's actually more likely a 1.5 HP unit.
 

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Thanks, Mr. J!
 

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It look like it ready for business , very nice improv. on phil design…enjoy and thanks for showing…BC
 

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So nicely made and you're making it stand in the corner ! : ) LOL
 

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Nice job. Thanks for the links! Looks really efficient. I like that it's all-in-one.

I've been concerned with the dust generated by everything. The shop vac does a good job, but I have to wack the filter every couple hours or so. Not so sure I get all the dust, micron level etc.

I've been researching the different styles. I checked out Bill Pentz's version, but now I have to check this one out too!

Do you have any stats on how much air cfm moves through the system?

I just watched the video! Wow! That thing works great…! It' really easier to make too. Hmmmm…. ;-)
 

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Ron,
I'm not sure exactly how much CFM runs through the system as I don't have any means to test that. Harbor Freight claims that the stock version runs something like 1350 CFM, but most people believe that is an exaggeration. It does have a reputation as being a pretty good DC, especially when you consider the bang for the buck when it's on sale. I got it for $139 at HF and just used the motor. In theory, my setup should be more efficient and higher in CFM's than the stock setup since its mounted directly in the barrel and not via a curved flex tube as well as the side inlet which eliminates another 45 degree bend had I mounted the elbow on the top. It's working very well. I haven't even noticed any dust coming out of the exhaust port as I haven't even vented it outside yet. It really does seem to capture all of the dust very well in my limited testing so far.
 

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I really like the design but my concern is the weight of the motor to lift each time that you need to empty the barrel, which could be several times a day.
Do you plan to have a lifting device or could it be possible to modify the barrel with a "drawer" on the bottom to empty it with out havering to lift the motor each time?

"I haven't even noticed any dust coming out of the exhaust port as I haven't even vented it outside yet"
Of course this does not mean that there is not very dangerous and harmful micro-particles which loge in your lungs and create all kind of health issues.
You really need to filter this air with a .05 micron filter.
 

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Great job, Michael !

Bert: When Sandor N shows this sort of modification in his book, "Woodshop Dust Control," he shows a simple block and tackle, used to lift the motor, and a simple wall-mounted cleat, used to tie off the cord while the motor is raised.

One day … I'll have to do this to mine … or … find a CraigsList deal on a Parts Puppy with a true 2HP motor, and a bigger impeller, or … something similar.

This idea just looks too good NOT to do :)
 

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What about using the same basic idea, bolted to the wall with bottom of the barrel cut and with a plastic bag on it?
 

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Micheal,
I just see that you posted this project 161 days ago.
How has the DC being working for you?
Did you made any additional modifications to it?
Did you install a filter?
 

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Bert, this has been working really well for me. I have been thinking about doing what Neil suggested with a block and tackle setup, but I don't have to empty it very often and it comes off pretty easily to set on the floor when I need to empty it. One nice thing about my setup is that I don't need a filter or a bag because I vent it out the side of my garage through a laundry vent. The separator captures so much that there's not really anything being exhausted out the vent. Take that back….I did have an issue when the separator was overfilled during planing. I'm thinking about putting a little window on it to view how full it is.
 

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Bert, one more thing…. when I said "I haven't even noticed any dust coming out of the exhaust port as I haven't even vented it outside yet" what I meant is that I hadn't installed my permanent solution yet which was a laundry exhaust vent. I was still exhausting it outside the garage using a longer hose that I ran underneath my garage door while slightly opened and didn't notice anything coming out. Being a 2 year cancer survivor, I'm pretty careful about things that might be bad for my health. :)
 

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Mike, Thank you for your answer.
I really like your idea but as I said I think that if or when I use it I shall install the barrel upside down, install the motor on the close end of the barrel and then install a plastic bag or something similar on the open end to make emptying easier.( I most likely could find a barrel to fit the existing plastic bags).
In addition I think that I might want to install an elbow on the fan suction to initiate the whirlpool air circulation to facilitate the separation of heavier particles.
This is a neat idea.
Again thank you for sharing
Have a good day.
Bert
 

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Bert,
Sounds like a good setup as well. I built mine with the idea of not having to mount anything. Also, there is no need for an elbow like many of the other separators you see because of the side mounted inlet pipe. It's really only necessary if you have both the suction and exhaust coming out of the top apparently. The air is drawn in and started in front of the separator baffle with the side inlet pipe in the same way it is with an elbow. I hope that makes sense. The side inlet pipe is supposed to be a way to increase efficiency and airflow as comparted to a 45 degree bend in an elbow.
 

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Mike you are 100% correct about the elbow.
It will be while before I do mine.
Because I exhaust the air in my shop , I also will use a cartridge filter , not yet done either.
 
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