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Discussion Starter · #1 ·
Making an Internal Thien Baffle for a HF Dust Collector

I was lucky enough to get the popular Harbor Freight 2 HP dust collector for Christmas. People have modified that thing in every way imaginable, so I found plenty of inspiration out there when planning what to do with mine. I decided to keep it fairly simple: a Thien baffle inside the dust collector's separator ring, to hopefully keep the dust in the bag and not in the filter. A lot of people have done this mod, but most of them don't post pictures because it is so simple. So I figured a quick pictorial of how I made mine might help someone in the future.

I used 1/4" MDF for the baffle. Many people use hardboard, but I have a really hard time finding stuff that is smooth on both sides. First I laid out the dimensions: 19" outer diameter with a 1.25" wide annular segment removed for 120 degrees of the circle.

Wood Rectangle Art Flooring Beige


I used my jigsaw to rough cut it out, making sure to cut outside the line.

Table Furniture Wood Flooring Floor


Next I rigged up a simple circle-cutting jig for my router table. I put my shop-vac hose close by to catch some of the MDF dust, but it still made a nasty mess.

Wood Table Flooring Composite material Automotive exterior


After cutting the drop slot with the jigsaw and router table (same way as before) and drilling 3 mounting holes, the baffle was complete.

Wood Table Floor Beige Art


To mount the baffle, I used 1" dowels and put hanger bolts in both ends. This way I could secure it with nuts and the baffle would be removable. The dowels need an angle on one end to mate with the dust collector ring, so I predrilled for the hanger bolt before cutting the angle.

Wood Floor Hardwood Flooring Wood stain


This allowed me to use the offcuts as angled washers.

Gas Plastic Auto part Electric blue Composite material


Fluid Gas Composite material Circle Plastic


Finally, I filled the center pivot hole in the baffle with epoxy and gave it a few coats of polyurethane. I did this so that hopefully the dust will stick to it a little less.

Table Furniture Tableware Wood Dishware


Wood Table Electronic instrument Audio equipment Musical instrument


In all, this baffle probably cost me about $15 for materials. In use, it definitely looks to be doing its job. Anyone who has this dust collector knows that the dust likes to swirl like a tornado in the bottom bag when it is turned on. This baffle has just about eliminated that swirling, so it should be keeping the filter bag cleaner. After using it for a few weeks, I noticed a few small leaks at the seam in the blower housing, so I sealed those with some caulk.

Automotive tire Fender Gas Bumper Thigh


I also put some weather stripping around the bottom of the collector ring where the lower bag seats. Those efforts seem to have sealed things up nicely.

Right now I just use this dust collector for my tablesaw, and it works very well. It definitely cuts down on the mess I make quite a bit. Eventually I will have a jointer and planer as well, and will hook it up to those. I'm sure it isn't the best dust collector out there by a long shot, but fits my needs nicely and cost about $170 including the baffle. When I get the money I do plan to add a Wynn cartridge filter, but for now I'm pleased with what I have. Thanks for reading!

Gas Building Machine Wood Cylinder
 

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Making an Internal Thien Baffle for a HF Dust Collector

I was lucky enough to get the popular Harbor Freight 2 HP dust collector for Christmas. People have modified that thing in every way imaginable, so I found plenty of inspiration out there when planning what to do with mine. I decided to keep it fairly simple: a Thien baffle inside the dust collector's separator ring, to hopefully keep the dust in the bag and not in the filter. A lot of people have done this mod, but most of them don't post pictures because it is so simple. So I figured a quick pictorial of how I made mine might help someone in the future.

I used 1/4" MDF for the baffle. Many people use hardboard, but I have a really hard time finding stuff that is smooth on both sides. First I laid out the dimensions: 19" outer diameter with a 1.25" wide annular segment removed for 120 degrees of the circle.

Wood Rectangle Art Flooring Beige


I used my jigsaw to rough cut it out, making sure to cut outside the line.

Table Furniture Wood Flooring Floor


Next I rigged up a simple circle-cutting jig for my router table. I put my shop-vac hose close by to catch some of the MDF dust, but it still made a nasty mess.

Wood Table Flooring Composite material Automotive exterior


After cutting the drop slot with the jigsaw and router table (same way as before) and drilling 3 mounting holes, the baffle was complete.

Wood Table Floor Beige Art


To mount the baffle, I used 1" dowels and put hanger bolts in both ends. This way I could secure it with nuts and the baffle would be removable. The dowels need an angle on one end to mate with the dust collector ring, so I predrilled for the hanger bolt before cutting the angle.

Wood Floor Hardwood Flooring Wood stain


This allowed me to use the offcuts as angled washers.

Gas Plastic Auto part Electric blue Composite material


Fluid Gas Composite material Circle Plastic


Finally, I filled the center pivot hole in the baffle with epoxy and gave it a few coats of polyurethane. I did this so that hopefully the dust will stick to it a little less.

Table Furniture Tableware Wood Dishware


Wood Table Electronic instrument Audio equipment Musical instrument


In all, this baffle probably cost me about $15 for materials. In use, it definitely looks to be doing its job. Anyone who has this dust collector knows that the dust likes to swirl like a tornado in the bottom bag when it is turned on. This baffle has just about eliminated that swirling, so it should be keeping the filter bag cleaner. After using it for a few weeks, I noticed a few small leaks at the seam in the blower housing, so I sealed those with some caulk.

Automotive tire Fender Gas Bumper Thigh


I also put some weather stripping around the bottom of the collector ring where the lower bag seats. Those efforts seem to have sealed things up nicely.

Right now I just use this dust collector for my tablesaw, and it works very well. It definitely cuts down on the mess I make quite a bit. Eventually I will have a jointer and planer as well, and will hook it up to those. I'm sure it isn't the best dust collector out there by a long shot, but fits my needs nicely and cost about $170 including the baffle. When I get the money I do plan to add a Wynn cartridge filter, but for now I'm pleased with what I have. Thanks for reading!

Gas Building Machine Wood Cylinder
Looks like it will work like a charm. Nice job, and nice "how-to" as well.
 

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Making an Internal Thien Baffle for a HF Dust Collector

I was lucky enough to get the popular Harbor Freight 2 HP dust collector for Christmas. People have modified that thing in every way imaginable, so I found plenty of inspiration out there when planning what to do with mine. I decided to keep it fairly simple: a Thien baffle inside the dust collector's separator ring, to hopefully keep the dust in the bag and not in the filter. A lot of people have done this mod, but most of them don't post pictures because it is so simple. So I figured a quick pictorial of how I made mine might help someone in the future.

I used 1/4" MDF for the baffle. Many people use hardboard, but I have a really hard time finding stuff that is smooth on both sides. First I laid out the dimensions: 19" outer diameter with a 1.25" wide annular segment removed for 120 degrees of the circle.

Wood Rectangle Art Flooring Beige


I used my jigsaw to rough cut it out, making sure to cut outside the line.

Table Furniture Wood Flooring Floor


Next I rigged up a simple circle-cutting jig for my router table. I put my shop-vac hose close by to catch some of the MDF dust, but it still made a nasty mess.

Wood Table Flooring Composite material Automotive exterior


After cutting the drop slot with the jigsaw and router table (same way as before) and drilling 3 mounting holes, the baffle was complete.

Wood Table Floor Beige Art


To mount the baffle, I used 1" dowels and put hanger bolts in both ends. This way I could secure it with nuts and the baffle would be removable. The dowels need an angle on one end to mate with the dust collector ring, so I predrilled for the hanger bolt before cutting the angle.

Wood Floor Hardwood Flooring Wood stain


This allowed me to use the offcuts as angled washers.

Gas Plastic Auto part Electric blue Composite material


Fluid Gas Composite material Circle Plastic


Finally, I filled the center pivot hole in the baffle with epoxy and gave it a few coats of polyurethane. I did this so that hopefully the dust will stick to it a little less.

Table Furniture Tableware Wood Dishware


Wood Table Electronic instrument Audio equipment Musical instrument


In all, this baffle probably cost me about $15 for materials. In use, it definitely looks to be doing its job. Anyone who has this dust collector knows that the dust likes to swirl like a tornado in the bottom bag when it is turned on. This baffle has just about eliminated that swirling, so it should be keeping the filter bag cleaner. After using it for a few weeks, I noticed a few small leaks at the seam in the blower housing, so I sealed those with some caulk.

Automotive tire Fender Gas Bumper Thigh


I also put some weather stripping around the bottom of the collector ring where the lower bag seats. Those efforts seem to have sealed things up nicely.

Right now I just use this dust collector for my tablesaw, and it works very well. It definitely cuts down on the mess I make quite a bit. Eventually I will have a jointer and planer as well, and will hook it up to those. I'm sure it isn't the best dust collector out there by a long shot, but fits my needs nicely and cost about $170 including the baffle. When I get the money I do plan to add a Wynn cartridge filter, but for now I'm pleased with what I have. Thanks for reading!

Gas Building Machine Wood Cylinder
Thanks for the pics
 

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Making an Internal Thien Baffle for a HF Dust Collector

I was lucky enough to get the popular Harbor Freight 2 HP dust collector for Christmas. People have modified that thing in every way imaginable, so I found plenty of inspiration out there when planning what to do with mine. I decided to keep it fairly simple: a Thien baffle inside the dust collector's separator ring, to hopefully keep the dust in the bag and not in the filter. A lot of people have done this mod, but most of them don't post pictures because it is so simple. So I figured a quick pictorial of how I made mine might help someone in the future.

I used 1/4" MDF for the baffle. Many people use hardboard, but I have a really hard time finding stuff that is smooth on both sides. First I laid out the dimensions: 19" outer diameter with a 1.25" wide annular segment removed for 120 degrees of the circle.

Wood Rectangle Art Flooring Beige


I used my jigsaw to rough cut it out, making sure to cut outside the line.

Table Furniture Wood Flooring Floor


Next I rigged up a simple circle-cutting jig for my router table. I put my shop-vac hose close by to catch some of the MDF dust, but it still made a nasty mess.

Wood Table Flooring Composite material Automotive exterior


After cutting the drop slot with the jigsaw and router table (same way as before) and drilling 3 mounting holes, the baffle was complete.

Wood Table Floor Beige Art


To mount the baffle, I used 1" dowels and put hanger bolts in both ends. This way I could secure it with nuts and the baffle would be removable. The dowels need an angle on one end to mate with the dust collector ring, so I predrilled for the hanger bolt before cutting the angle.

Wood Floor Hardwood Flooring Wood stain


This allowed me to use the offcuts as angled washers.

Gas Plastic Auto part Electric blue Composite material


Fluid Gas Composite material Circle Plastic


Finally, I filled the center pivot hole in the baffle with epoxy and gave it a few coats of polyurethane. I did this so that hopefully the dust will stick to it a little less.

Table Furniture Tableware Wood Dishware


Wood Table Electronic instrument Audio equipment Musical instrument


In all, this baffle probably cost me about $15 for materials. In use, it definitely looks to be doing its job. Anyone who has this dust collector knows that the dust likes to swirl like a tornado in the bottom bag when it is turned on. This baffle has just about eliminated that swirling, so it should be keeping the filter bag cleaner. After using it for a few weeks, I noticed a few small leaks at the seam in the blower housing, so I sealed those with some caulk.

Automotive tire Fender Gas Bumper Thigh


I also put some weather stripping around the bottom of the collector ring where the lower bag seats. Those efforts seem to have sealed things up nicely.

Right now I just use this dust collector for my tablesaw, and it works very well. It definitely cuts down on the mess I make quite a bit. Eventually I will have a jointer and planer as well, and will hook it up to those. I'm sure it isn't the best dust collector out there by a long shot, but fits my needs nicely and cost about $170 including the baffle. When I get the money I do plan to add a Wynn cartridge filter, but for now I'm pleased with what I have. Thanks for reading!

Gas Building Machine Wood Cylinder
I was wondering if this could be done, didn't want to mess with extra can and hoses for the Thien baffle. So how is it working out? Have you noticed a difference?
 

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Discussion Starter · #5 ·
Making an Internal Thien Baffle for a HF Dust Collector

I was lucky enough to get the popular Harbor Freight 2 HP dust collector for Christmas. People have modified that thing in every way imaginable, so I found plenty of inspiration out there when planning what to do with mine. I decided to keep it fairly simple: a Thien baffle inside the dust collector's separator ring, to hopefully keep the dust in the bag and not in the filter. A lot of people have done this mod, but most of them don't post pictures because it is so simple. So I figured a quick pictorial of how I made mine might help someone in the future.

I used 1/4" MDF for the baffle. Many people use hardboard, but I have a really hard time finding stuff that is smooth on both sides. First I laid out the dimensions: 19" outer diameter with a 1.25" wide annular segment removed for 120 degrees of the circle.

Wood Rectangle Art Flooring Beige


I used my jigsaw to rough cut it out, making sure to cut outside the line.

Table Furniture Wood Flooring Floor


Next I rigged up a simple circle-cutting jig for my router table. I put my shop-vac hose close by to catch some of the MDF dust, but it still made a nasty mess.

Wood Table Flooring Composite material Automotive exterior


After cutting the drop slot with the jigsaw and router table (same way as before) and drilling 3 mounting holes, the baffle was complete.

Wood Table Floor Beige Art


To mount the baffle, I used 1" dowels and put hanger bolts in both ends. This way I could secure it with nuts and the baffle would be removable. The dowels need an angle on one end to mate with the dust collector ring, so I predrilled for the hanger bolt before cutting the angle.

Wood Floor Hardwood Flooring Wood stain


This allowed me to use the offcuts as angled washers.

Gas Plastic Auto part Electric blue Composite material


Fluid Gas Composite material Circle Plastic


Finally, I filled the center pivot hole in the baffle with epoxy and gave it a few coats of polyurethane. I did this so that hopefully the dust will stick to it a little less.

Table Furniture Tableware Wood Dishware


Wood Table Electronic instrument Audio equipment Musical instrument


In all, this baffle probably cost me about $15 for materials. In use, it definitely looks to be doing its job. Anyone who has this dust collector knows that the dust likes to swirl like a tornado in the bottom bag when it is turned on. This baffle has just about eliminated that swirling, so it should be keeping the filter bag cleaner. After using it for a few weeks, I noticed a few small leaks at the seam in the blower housing, so I sealed those with some caulk.

Automotive tire Fender Gas Bumper Thigh


I also put some weather stripping around the bottom of the collector ring where the lower bag seats. Those efforts seem to have sealed things up nicely.

Right now I just use this dust collector for my tablesaw, and it works very well. It definitely cuts down on the mess I make quite a bit. Eventually I will have a jointer and planer as well, and will hook it up to those. I'm sure it isn't the best dust collector out there by a long shot, but fits my needs nicely and cost about $170 including the baffle. When I get the money I do plan to add a Wynn cartridge filter, but for now I'm pleased with what I have. Thanks for reading!

Gas Building Machine Wood Cylinder
It does what it's supposed to. When I first bought this dust collector, the dust would swirl in the bottom bag like a tornado. The Thien baffle has stopped that swirling, and therefore the upper bag should be staying much cleaner. I'm definitely glad I did this. I'm not the first to put my Thien baffle in that location.

The advantages of an internal Thien baffle are:
  • Simple construction
  • Space and material savings
  • No pressure drop

The advantages of an external Thien separator are:
  • Keeps filter even cleaner if working correctly
  • Separates large chips and debris before they hit the impeller
  • Easier to empty when full
 

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Making an Internal Thien Baffle for a HF Dust Collector

I was lucky enough to get the popular Harbor Freight 2 HP dust collector for Christmas. People have modified that thing in every way imaginable, so I found plenty of inspiration out there when planning what to do with mine. I decided to keep it fairly simple: a Thien baffle inside the dust collector's separator ring, to hopefully keep the dust in the bag and not in the filter. A lot of people have done this mod, but most of them don't post pictures because it is so simple. So I figured a quick pictorial of how I made mine might help someone in the future.

I used 1/4" MDF for the baffle. Many people use hardboard, but I have a really hard time finding stuff that is smooth on both sides. First I laid out the dimensions: 19" outer diameter with a 1.25" wide annular segment removed for 120 degrees of the circle.

Wood Rectangle Art Flooring Beige


I used my jigsaw to rough cut it out, making sure to cut outside the line.

Table Furniture Wood Flooring Floor


Next I rigged up a simple circle-cutting jig for my router table. I put my shop-vac hose close by to catch some of the MDF dust, but it still made a nasty mess.

Wood Table Flooring Composite material Automotive exterior


After cutting the drop slot with the jigsaw and router table (same way as before) and drilling 3 mounting holes, the baffle was complete.

Wood Table Floor Beige Art


To mount the baffle, I used 1" dowels and put hanger bolts in both ends. This way I could secure it with nuts and the baffle would be removable. The dowels need an angle on one end to mate with the dust collector ring, so I predrilled for the hanger bolt before cutting the angle.

Wood Floor Hardwood Flooring Wood stain


This allowed me to use the offcuts as angled washers.

Gas Plastic Auto part Electric blue Composite material


Fluid Gas Composite material Circle Plastic


Finally, I filled the center pivot hole in the baffle with epoxy and gave it a few coats of polyurethane. I did this so that hopefully the dust will stick to it a little less.

Table Furniture Tableware Wood Dishware


Wood Table Electronic instrument Audio equipment Musical instrument


In all, this baffle probably cost me about $15 for materials. In use, it definitely looks to be doing its job. Anyone who has this dust collector knows that the dust likes to swirl like a tornado in the bottom bag when it is turned on. This baffle has just about eliminated that swirling, so it should be keeping the filter bag cleaner. After using it for a few weeks, I noticed a few small leaks at the seam in the blower housing, so I sealed those with some caulk.

Automotive tire Fender Gas Bumper Thigh


I also put some weather stripping around the bottom of the collector ring where the lower bag seats. Those efforts seem to have sealed things up nicely.

Right now I just use this dust collector for my tablesaw, and it works very well. It definitely cuts down on the mess I make quite a bit. Eventually I will have a jointer and planer as well, and will hook it up to those. I'm sure it isn't the best dust collector out there by a long shot, but fits my needs nicely and cost about $170 including the baffle. When I get the money I do plan to add a Wynn cartridge filter, but for now I'm pleased with what I have. Thanks for reading!

Gas Building Machine Wood Cylinder
Nice. Thanks for the pictoral
 

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Making an Internal Thien Baffle for a HF Dust Collector

I was lucky enough to get the popular Harbor Freight 2 HP dust collector for Christmas. People have modified that thing in every way imaginable, so I found plenty of inspiration out there when planning what to do with mine. I decided to keep it fairly simple: a Thien baffle inside the dust collector's separator ring, to hopefully keep the dust in the bag and not in the filter. A lot of people have done this mod, but most of them don't post pictures because it is so simple. So I figured a quick pictorial of how I made mine might help someone in the future.

I used 1/4" MDF for the baffle. Many people use hardboard, but I have a really hard time finding stuff that is smooth on both sides. First I laid out the dimensions: 19" outer diameter with a 1.25" wide annular segment removed for 120 degrees of the circle.

Wood Rectangle Art Flooring Beige


I used my jigsaw to rough cut it out, making sure to cut outside the line.

Table Furniture Wood Flooring Floor


Next I rigged up a simple circle-cutting jig for my router table. I put my shop-vac hose close by to catch some of the MDF dust, but it still made a nasty mess.

Wood Table Flooring Composite material Automotive exterior


After cutting the drop slot with the jigsaw and router table (same way as before) and drilling 3 mounting holes, the baffle was complete.

Wood Table Floor Beige Art


To mount the baffle, I used 1" dowels and put hanger bolts in both ends. This way I could secure it with nuts and the baffle would be removable. The dowels need an angle on one end to mate with the dust collector ring, so I predrilled for the hanger bolt before cutting the angle.

Wood Floor Hardwood Flooring Wood stain


This allowed me to use the offcuts as angled washers.

Gas Plastic Auto part Electric blue Composite material


Fluid Gas Composite material Circle Plastic


Finally, I filled the center pivot hole in the baffle with epoxy and gave it a few coats of polyurethane. I did this so that hopefully the dust will stick to it a little less.

Table Furniture Tableware Wood Dishware


Wood Table Electronic instrument Audio equipment Musical instrument


In all, this baffle probably cost me about $15 for materials. In use, it definitely looks to be doing its job. Anyone who has this dust collector knows that the dust likes to swirl like a tornado in the bottom bag when it is turned on. This baffle has just about eliminated that swirling, so it should be keeping the filter bag cleaner. After using it for a few weeks, I noticed a few small leaks at the seam in the blower housing, so I sealed those with some caulk.

Automotive tire Fender Gas Bumper Thigh


I also put some weather stripping around the bottom of the collector ring where the lower bag seats. Those efforts seem to have sealed things up nicely.

Right now I just use this dust collector for my tablesaw, and it works very well. It definitely cuts down on the mess I make quite a bit. Eventually I will have a jointer and planer as well, and will hook it up to those. I'm sure it isn't the best dust collector out there by a long shot, but fits my needs nicely and cost about $170 including the baffle. When I get the money I do plan to add a Wynn cartridge filter, but for now I'm pleased with what I have. Thanks for reading!

Gas Building Machine Wood Cylinder
Cool. Thanks Rex! I ordered the Wynn filter yesterday. So will get both installed this next week. Another member over on Family Woodworking had used a wok pan mounted in his upside down, which does about the same, but I've got the MDF and dowels for doing the Thien method.
 

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Making an Internal Thien Baffle for a HF Dust Collector

I was lucky enough to get the popular Harbor Freight 2 HP dust collector for Christmas. People have modified that thing in every way imaginable, so I found plenty of inspiration out there when planning what to do with mine. I decided to keep it fairly simple: a Thien baffle inside the dust collector's separator ring, to hopefully keep the dust in the bag and not in the filter. A lot of people have done this mod, but most of them don't post pictures because it is so simple. So I figured a quick pictorial of how I made mine might help someone in the future.

I used 1/4" MDF for the baffle. Many people use hardboard, but I have a really hard time finding stuff that is smooth on both sides. First I laid out the dimensions: 19" outer diameter with a 1.25" wide annular segment removed for 120 degrees of the circle.

Wood Rectangle Art Flooring Beige


I used my jigsaw to rough cut it out, making sure to cut outside the line.

Table Furniture Wood Flooring Floor


Next I rigged up a simple circle-cutting jig for my router table. I put my shop-vac hose close by to catch some of the MDF dust, but it still made a nasty mess.

Wood Table Flooring Composite material Automotive exterior


After cutting the drop slot with the jigsaw and router table (same way as before) and drilling 3 mounting holes, the baffle was complete.

Wood Table Floor Beige Art


To mount the baffle, I used 1" dowels and put hanger bolts in both ends. This way I could secure it with nuts and the baffle would be removable. The dowels need an angle on one end to mate with the dust collector ring, so I predrilled for the hanger bolt before cutting the angle.

Wood Floor Hardwood Flooring Wood stain


This allowed me to use the offcuts as angled washers.

Gas Plastic Auto part Electric blue Composite material


Fluid Gas Composite material Circle Plastic


Finally, I filled the center pivot hole in the baffle with epoxy and gave it a few coats of polyurethane. I did this so that hopefully the dust will stick to it a little less.

Table Furniture Tableware Wood Dishware


Wood Table Electronic instrument Audio equipment Musical instrument


In all, this baffle probably cost me about $15 for materials. In use, it definitely looks to be doing its job. Anyone who has this dust collector knows that the dust likes to swirl like a tornado in the bottom bag when it is turned on. This baffle has just about eliminated that swirling, so it should be keeping the filter bag cleaner. After using it for a few weeks, I noticed a few small leaks at the seam in the blower housing, so I sealed those with some caulk.

Automotive tire Fender Gas Bumper Thigh


I also put some weather stripping around the bottom of the collector ring where the lower bag seats. Those efforts seem to have sealed things up nicely.

Right now I just use this dust collector for my tablesaw, and it works very well. It definitely cuts down on the mess I make quite a bit. Eventually I will have a jointer and planer as well, and will hook it up to those. I'm sure it isn't the best dust collector out there by a long shot, but fits my needs nicely and cost about $170 including the baffle. When I get the money I do plan to add a Wynn cartridge filter, but for now I'm pleased with what I have. Thanks for reading!

Gas Building Machine Wood Cylinder
Can the internal baffle be used with an canister filter, like a Wynn 35Axxx?
 

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Making an Internal Thien Baffle for a HF Dust Collector

I was lucky enough to get the popular Harbor Freight 2 HP dust collector for Christmas. People have modified that thing in every way imaginable, so I found plenty of inspiration out there when planning what to do with mine. I decided to keep it fairly simple: a Thien baffle inside the dust collector's separator ring, to hopefully keep the dust in the bag and not in the filter. A lot of people have done this mod, but most of them don't post pictures because it is so simple. So I figured a quick pictorial of how I made mine might help someone in the future.

I used 1/4" MDF for the baffle. Many people use hardboard, but I have a really hard time finding stuff that is smooth on both sides. First I laid out the dimensions: 19" outer diameter with a 1.25" wide annular segment removed for 120 degrees of the circle.

Wood Rectangle Art Flooring Beige


I used my jigsaw to rough cut it out, making sure to cut outside the line.

Table Furniture Wood Flooring Floor


Next I rigged up a simple circle-cutting jig for my router table. I put my shop-vac hose close by to catch some of the MDF dust, but it still made a nasty mess.

Wood Table Flooring Composite material Automotive exterior


After cutting the drop slot with the jigsaw and router table (same way as before) and drilling 3 mounting holes, the baffle was complete.

Wood Table Floor Beige Art


To mount the baffle, I used 1" dowels and put hanger bolts in both ends. This way I could secure it with nuts and the baffle would be removable. The dowels need an angle on one end to mate with the dust collector ring, so I predrilled for the hanger bolt before cutting the angle.

Wood Floor Hardwood Flooring Wood stain


This allowed me to use the offcuts as angled washers.

Gas Plastic Auto part Electric blue Composite material


Fluid Gas Composite material Circle Plastic


Finally, I filled the center pivot hole in the baffle with epoxy and gave it a few coats of polyurethane. I did this so that hopefully the dust will stick to it a little less.

Table Furniture Tableware Wood Dishware


Wood Table Electronic instrument Audio equipment Musical instrument


In all, this baffle probably cost me about $15 for materials. In use, it definitely looks to be doing its job. Anyone who has this dust collector knows that the dust likes to swirl like a tornado in the bottom bag when it is turned on. This baffle has just about eliminated that swirling, so it should be keeping the filter bag cleaner. After using it for a few weeks, I noticed a few small leaks at the seam in the blower housing, so I sealed those with some caulk.

Automotive tire Fender Gas Bumper Thigh


I also put some weather stripping around the bottom of the collector ring where the lower bag seats. Those efforts seem to have sealed things up nicely.

Right now I just use this dust collector for my tablesaw, and it works very well. It definitely cuts down on the mess I make quite a bit. Eventually I will have a jointer and planer as well, and will hook it up to those. I'm sure it isn't the best dust collector out there by a long shot, but fits my needs nicely and cost about $170 including the baffle. When I get the money I do plan to add a Wynn cartridge filter, but for now I'm pleased with what I have. Thanks for reading!

Gas Building Machine Wood Cylinder
DW833,
YES!
 

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Discussion Starter · #10 ·
Making an Internal Thien Baffle for a HF Dust Collector

I was lucky enough to get the popular Harbor Freight 2 HP dust collector for Christmas. People have modified that thing in every way imaginable, so I found plenty of inspiration out there when planning what to do with mine. I decided to keep it fairly simple: a Thien baffle inside the dust collector's separator ring, to hopefully keep the dust in the bag and not in the filter. A lot of people have done this mod, but most of them don't post pictures because it is so simple. So I figured a quick pictorial of how I made mine might help someone in the future.

I used 1/4" MDF for the baffle. Many people use hardboard, but I have a really hard time finding stuff that is smooth on both sides. First I laid out the dimensions: 19" outer diameter with a 1.25" wide annular segment removed for 120 degrees of the circle.

Wood Rectangle Art Flooring Beige


I used my jigsaw to rough cut it out, making sure to cut outside the line.

Table Furniture Wood Flooring Floor


Next I rigged up a simple circle-cutting jig for my router table. I put my shop-vac hose close by to catch some of the MDF dust, but it still made a nasty mess.

Wood Table Flooring Composite material Automotive exterior


After cutting the drop slot with the jigsaw and router table (same way as before) and drilling 3 mounting holes, the baffle was complete.

Wood Table Floor Beige Art


To mount the baffle, I used 1" dowels and put hanger bolts in both ends. This way I could secure it with nuts and the baffle would be removable. The dowels need an angle on one end to mate with the dust collector ring, so I predrilled for the hanger bolt before cutting the angle.

Wood Floor Hardwood Flooring Wood stain


This allowed me to use the offcuts as angled washers.

Gas Plastic Auto part Electric blue Composite material


Fluid Gas Composite material Circle Plastic


Finally, I filled the center pivot hole in the baffle with epoxy and gave it a few coats of polyurethane. I did this so that hopefully the dust will stick to it a little less.

Table Furniture Tableware Wood Dishware


Wood Table Electronic instrument Audio equipment Musical instrument


In all, this baffle probably cost me about $15 for materials. In use, it definitely looks to be doing its job. Anyone who has this dust collector knows that the dust likes to swirl like a tornado in the bottom bag when it is turned on. This baffle has just about eliminated that swirling, so it should be keeping the filter bag cleaner. After using it for a few weeks, I noticed a few small leaks at the seam in the blower housing, so I sealed those with some caulk.

Automotive tire Fender Gas Bumper Thigh


I also put some weather stripping around the bottom of the collector ring where the lower bag seats. Those efforts seem to have sealed things up nicely.

Right now I just use this dust collector for my tablesaw, and it works very well. It definitely cuts down on the mess I make quite a bit. Eventually I will have a jointer and planer as well, and will hook it up to those. I'm sure it isn't the best dust collector out there by a long shot, but fits my needs nicely and cost about $170 including the baffle. When I get the money I do plan to add a Wynn cartridge filter, but for now I'm pleased with what I have. Thanks for reading!

Gas Building Machine Wood Cylinder
DW833 - as DIYaholic said, YES! The main purpose of the baffle is to keep the filter clean, which is mostly a concern when using a canister filter. I just haven't upgraded my filter yet, but I will as my budget allows.
 

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Making an Internal Thien Baffle for a HF Dust Collector

I was lucky enough to get the popular Harbor Freight 2 HP dust collector for Christmas. People have modified that thing in every way imaginable, so I found plenty of inspiration out there when planning what to do with mine. I decided to keep it fairly simple: a Thien baffle inside the dust collector's separator ring, to hopefully keep the dust in the bag and not in the filter. A lot of people have done this mod, but most of them don't post pictures because it is so simple. So I figured a quick pictorial of how I made mine might help someone in the future.

I used 1/4" MDF for the baffle. Many people use hardboard, but I have a really hard time finding stuff that is smooth on both sides. First I laid out the dimensions: 19" outer diameter with a 1.25" wide annular segment removed for 120 degrees of the circle.

Wood Rectangle Art Flooring Beige


I used my jigsaw to rough cut it out, making sure to cut outside the line.

Table Furniture Wood Flooring Floor


Next I rigged up a simple circle-cutting jig for my router table. I put my shop-vac hose close by to catch some of the MDF dust, but it still made a nasty mess.

Wood Table Flooring Composite material Automotive exterior


After cutting the drop slot with the jigsaw and router table (same way as before) and drilling 3 mounting holes, the baffle was complete.

Wood Table Floor Beige Art


To mount the baffle, I used 1" dowels and put hanger bolts in both ends. This way I could secure it with nuts and the baffle would be removable. The dowels need an angle on one end to mate with the dust collector ring, so I predrilled for the hanger bolt before cutting the angle.

Wood Floor Hardwood Flooring Wood stain


This allowed me to use the offcuts as angled washers.

Gas Plastic Auto part Electric blue Composite material


Fluid Gas Composite material Circle Plastic


Finally, I filled the center pivot hole in the baffle with epoxy and gave it a few coats of polyurethane. I did this so that hopefully the dust will stick to it a little less.

Table Furniture Tableware Wood Dishware


Wood Table Electronic instrument Audio equipment Musical instrument


In all, this baffle probably cost me about $15 for materials. In use, it definitely looks to be doing its job. Anyone who has this dust collector knows that the dust likes to swirl like a tornado in the bottom bag when it is turned on. This baffle has just about eliminated that swirling, so it should be keeping the filter bag cleaner. After using it for a few weeks, I noticed a few small leaks at the seam in the blower housing, so I sealed those with some caulk.

Automotive tire Fender Gas Bumper Thigh


I also put some weather stripping around the bottom of the collector ring where the lower bag seats. Those efforts seem to have sealed things up nicely.

Right now I just use this dust collector for my tablesaw, and it works very well. It definitely cuts down on the mess I make quite a bit. Eventually I will have a jointer and planer as well, and will hook it up to those. I'm sure it isn't the best dust collector out there by a long shot, but fits my needs nicely and cost about $170 including the baffle. When I get the money I do plan to add a Wynn cartridge filter, but for now I'm pleased with what I have. Thanks for reading!

Gas Building Machine Wood Cylinder
Dear Rex B
I just finished talking with Dick Wynn, and he said your method is definitely the right way to go. It wasn't an endorsement just that it was definitely the correct way to go.

I made the mistake of letting my Wynn air filter get too congested. It took a long time to clean it out. Dick mentioned that never let the debris bag get more than a quarter full although with the installation of this baffle you can get it let it get fuller, maybe half.

Dick also mentioned never wash the filter. Use compressed air not above 80 psi. and the combination of dropping it against the ground from a height of 2 to 3 inches so's not to damage the filter or the housing.

Just thought I'd pass what I just learned along . . .

Dick Wynn sounded very approachable and eager to help in anyway you could. He invited my call again should I have more questions. Great customer service!
 

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Making an Internal Thien Baffle for a HF Dust Collector

I was lucky enough to get the popular Harbor Freight 2 HP dust collector for Christmas. People have modified that thing in every way imaginable, so I found plenty of inspiration out there when planning what to do with mine. I decided to keep it fairly simple: a Thien baffle inside the dust collector's separator ring, to hopefully keep the dust in the bag and not in the filter. A lot of people have done this mod, but most of them don't post pictures because it is so simple. So I figured a quick pictorial of how I made mine might help someone in the future.

I used 1/4" MDF for the baffle. Many people use hardboard, but I have a really hard time finding stuff that is smooth on both sides. First I laid out the dimensions: 19" outer diameter with a 1.25" wide annular segment removed for 120 degrees of the circle.

Wood Rectangle Art Flooring Beige


I used my jigsaw to rough cut it out, making sure to cut outside the line.

Table Furniture Wood Flooring Floor


Next I rigged up a simple circle-cutting jig for my router table. I put my shop-vac hose close by to catch some of the MDF dust, but it still made a nasty mess.

Wood Table Flooring Composite material Automotive exterior


After cutting the drop slot with the jigsaw and router table (same way as before) and drilling 3 mounting holes, the baffle was complete.

Wood Table Floor Beige Art


To mount the baffle, I used 1" dowels and put hanger bolts in both ends. This way I could secure it with nuts and the baffle would be removable. The dowels need an angle on one end to mate with the dust collector ring, so I predrilled for the hanger bolt before cutting the angle.

Wood Floor Hardwood Flooring Wood stain


This allowed me to use the offcuts as angled washers.

Gas Plastic Auto part Electric blue Composite material


Fluid Gas Composite material Circle Plastic


Finally, I filled the center pivot hole in the baffle with epoxy and gave it a few coats of polyurethane. I did this so that hopefully the dust will stick to it a little less.

Table Furniture Tableware Wood Dishware


Wood Table Electronic instrument Audio equipment Musical instrument


In all, this baffle probably cost me about $15 for materials. In use, it definitely looks to be doing its job. Anyone who has this dust collector knows that the dust likes to swirl like a tornado in the bottom bag when it is turned on. This baffle has just about eliminated that swirling, so it should be keeping the filter bag cleaner. After using it for a few weeks, I noticed a few small leaks at the seam in the blower housing, so I sealed those with some caulk.

Automotive tire Fender Gas Bumper Thigh


I also put some weather stripping around the bottom of the collector ring where the lower bag seats. Those efforts seem to have sealed things up nicely.

Right now I just use this dust collector for my tablesaw, and it works very well. It definitely cuts down on the mess I make quite a bit. Eventually I will have a jointer and planer as well, and will hook it up to those. I'm sure it isn't the best dust collector out there by a long shot, but fits my needs nicely and cost about $170 including the baffle. When I get the money I do plan to add a Wynn cartridge filter, but for now I'm pleased with what I have. Thanks for reading!

Gas Building Machine Wood Cylinder
Dear Rex B
I just finished talking with Dick Wynn, and he said your method is definitely the right way to go. It wasn't an endorsement just that it was definitely the correct way to go.

I made the mistake of letting my Wynn air filter get too congested. It took a long time to clean it out. Dick mentioned that never let the debris bag get more than a quarter full although with the installation of this baffle you can get it let it get fuller, maybe half.

Dick also mentioned never wash the filter. Use compressed air not above 80 psi. and the combination of dropping it against the ground from a height of 2 to 3 inches so's not to damage the filter or the housing.

Just thought I'd pass what I just learned along . . .

Dick Wynn sounded very approachable and eager to help in anyway you could. He invited my call again should I have more questions. Great customer service!
 

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Making an Internal Thien Baffle for a HF Dust Collector

I was lucky enough to get the popular Harbor Freight 2 HP dust collector for Christmas. People have modified that thing in every way imaginable, so I found plenty of inspiration out there when planning what to do with mine. I decided to keep it fairly simple: a Thien baffle inside the dust collector's separator ring, to hopefully keep the dust in the bag and not in the filter. A lot of people have done this mod, but most of them don't post pictures because it is so simple. So I figured a quick pictorial of how I made mine might help someone in the future.

I used 1/4" MDF for the baffle. Many people use hardboard, but I have a really hard time finding stuff that is smooth on both sides. First I laid out the dimensions: 19" outer diameter with a 1.25" wide annular segment removed for 120 degrees of the circle.

Wood Rectangle Art Flooring Beige


I used my jigsaw to rough cut it out, making sure to cut outside the line.

Table Furniture Wood Flooring Floor


Next I rigged up a simple circle-cutting jig for my router table. I put my shop-vac hose close by to catch some of the MDF dust, but it still made a nasty mess.

Wood Table Flooring Composite material Automotive exterior


After cutting the drop slot with the jigsaw and router table (same way as before) and drilling 3 mounting holes, the baffle was complete.

Wood Table Floor Beige Art


To mount the baffle, I used 1" dowels and put hanger bolts in both ends. This way I could secure it with nuts and the baffle would be removable. The dowels need an angle on one end to mate with the dust collector ring, so I predrilled for the hanger bolt before cutting the angle.

Wood Floor Hardwood Flooring Wood stain


This allowed me to use the offcuts as angled washers.

Gas Plastic Auto part Electric blue Composite material


Fluid Gas Composite material Circle Plastic


Finally, I filled the center pivot hole in the baffle with epoxy and gave it a few coats of polyurethane. I did this so that hopefully the dust will stick to it a little less.

Table Furniture Tableware Wood Dishware


Wood Table Electronic instrument Audio equipment Musical instrument


In all, this baffle probably cost me about $15 for materials. In use, it definitely looks to be doing its job. Anyone who has this dust collector knows that the dust likes to swirl like a tornado in the bottom bag when it is turned on. This baffle has just about eliminated that swirling, so it should be keeping the filter bag cleaner. After using it for a few weeks, I noticed a few small leaks at the seam in the blower housing, so I sealed those with some caulk.

Automotive tire Fender Gas Bumper Thigh


I also put some weather stripping around the bottom of the collector ring where the lower bag seats. Those efforts seem to have sealed things up nicely.

Right now I just use this dust collector for my tablesaw, and it works very well. It definitely cuts down on the mess I make quite a bit. Eventually I will have a jointer and planer as well, and will hook it up to those. I'm sure it isn't the best dust collector out there by a long shot, but fits my needs nicely and cost about $170 including the baffle. When I get the money I do plan to add a Wynn cartridge filter, but for now I'm pleased with what I have. Thanks for reading!

Gas Building Machine Wood Cylinder
REX - What is the length of the 1" dowels you used and how far does this put the baffle from the cove surface?
 

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Discussion Starter · #14 ·
Making an Internal Thien Baffle for a HF Dust Collector

I was lucky enough to get the popular Harbor Freight 2 HP dust collector for Christmas. People have modified that thing in every way imaginable, so I found plenty of inspiration out there when planning what to do with mine. I decided to keep it fairly simple: a Thien baffle inside the dust collector's separator ring, to hopefully keep the dust in the bag and not in the filter. A lot of people have done this mod, but most of them don't post pictures because it is so simple. So I figured a quick pictorial of how I made mine might help someone in the future.

I used 1/4" MDF for the baffle. Many people use hardboard, but I have a really hard time finding stuff that is smooth on both sides. First I laid out the dimensions: 19" outer diameter with a 1.25" wide annular segment removed for 120 degrees of the circle.

Wood Rectangle Art Flooring Beige


I used my jigsaw to rough cut it out, making sure to cut outside the line.

Table Furniture Wood Flooring Floor


Next I rigged up a simple circle-cutting jig for my router table. I put my shop-vac hose close by to catch some of the MDF dust, but it still made a nasty mess.

Wood Table Flooring Composite material Automotive exterior


After cutting the drop slot with the jigsaw and router table (same way as before) and drilling 3 mounting holes, the baffle was complete.

Wood Table Floor Beige Art


To mount the baffle, I used 1" dowels and put hanger bolts in both ends. This way I could secure it with nuts and the baffle would be removable. The dowels need an angle on one end to mate with the dust collector ring, so I predrilled for the hanger bolt before cutting the angle.

Wood Floor Hardwood Flooring Wood stain


This allowed me to use the offcuts as angled washers.

Gas Plastic Auto part Electric blue Composite material


Fluid Gas Composite material Circle Plastic


Finally, I filled the center pivot hole in the baffle with epoxy and gave it a few coats of polyurethane. I did this so that hopefully the dust will stick to it a little less.

Table Furniture Tableware Wood Dishware


Wood Table Electronic instrument Audio equipment Musical instrument


In all, this baffle probably cost me about $15 for materials. In use, it definitely looks to be doing its job. Anyone who has this dust collector knows that the dust likes to swirl like a tornado in the bottom bag when it is turned on. This baffle has just about eliminated that swirling, so it should be keeping the filter bag cleaner. After using it for a few weeks, I noticed a few small leaks at the seam in the blower housing, so I sealed those with some caulk.

Automotive tire Fender Gas Bumper Thigh


I also put some weather stripping around the bottom of the collector ring where the lower bag seats. Those efforts seem to have sealed things up nicely.

Right now I just use this dust collector for my tablesaw, and it works very well. It definitely cuts down on the mess I make quite a bit. Eventually I will have a jointer and planer as well, and will hook it up to those. I'm sure it isn't the best dust collector out there by a long shot, but fits my needs nicely and cost about $170 including the baffle. When I get the money I do plan to add a Wynn cartridge filter, but for now I'm pleased with what I have. Thanks for reading!

Gas Building Machine Wood Cylinder
Dorald, I don't know what length the dowels are exactly, but they put the baffle right above the bent lip at the bottom of the DC ring, as you can kind of see in one of the pictures above.
 

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Making an Internal Thien Baffle for a HF Dust Collector

I was lucky enough to get the popular Harbor Freight 2 HP dust collector for Christmas. People have modified that thing in every way imaginable, so I found plenty of inspiration out there when planning what to do with mine. I decided to keep it fairly simple: a Thien baffle inside the dust collector's separator ring, to hopefully keep the dust in the bag and not in the filter. A lot of people have done this mod, but most of them don't post pictures because it is so simple. So I figured a quick pictorial of how I made mine might help someone in the future.

I used 1/4" MDF for the baffle. Many people use hardboard, but I have a really hard time finding stuff that is smooth on both sides. First I laid out the dimensions: 19" outer diameter with a 1.25" wide annular segment removed for 120 degrees of the circle.

Wood Rectangle Art Flooring Beige


I used my jigsaw to rough cut it out, making sure to cut outside the line.

Table Furniture Wood Flooring Floor


Next I rigged up a simple circle-cutting jig for my router table. I put my shop-vac hose close by to catch some of the MDF dust, but it still made a nasty mess.

Wood Table Flooring Composite material Automotive exterior


After cutting the drop slot with the jigsaw and router table (same way as before) and drilling 3 mounting holes, the baffle was complete.

Wood Table Floor Beige Art


To mount the baffle, I used 1" dowels and put hanger bolts in both ends. This way I could secure it with nuts and the baffle would be removable. The dowels need an angle on one end to mate with the dust collector ring, so I predrilled for the hanger bolt before cutting the angle.

Wood Floor Hardwood Flooring Wood stain


This allowed me to use the offcuts as angled washers.

Gas Plastic Auto part Electric blue Composite material


Fluid Gas Composite material Circle Plastic


Finally, I filled the center pivot hole in the baffle with epoxy and gave it a few coats of polyurethane. I did this so that hopefully the dust will stick to it a little less.

Table Furniture Tableware Wood Dishware


Wood Table Electronic instrument Audio equipment Musical instrument


In all, this baffle probably cost me about $15 for materials. In use, it definitely looks to be doing its job. Anyone who has this dust collector knows that the dust likes to swirl like a tornado in the bottom bag when it is turned on. This baffle has just about eliminated that swirling, so it should be keeping the filter bag cleaner. After using it for a few weeks, I noticed a few small leaks at the seam in the blower housing, so I sealed those with some caulk.

Automotive tire Fender Gas Bumper Thigh


I also put some weather stripping around the bottom of the collector ring where the lower bag seats. Those efforts seem to have sealed things up nicely.

Right now I just use this dust collector for my tablesaw, and it works very well. It definitely cuts down on the mess I make quite a bit. Eventually I will have a jointer and planer as well, and will hook it up to those. I'm sure it isn't the best dust collector out there by a long shot, but fits my needs nicely and cost about $170 including the baffle. When I get the money I do plan to add a Wynn cartridge filter, but for now I'm pleased with what I have. Thanks for reading!

Gas Building Machine Wood Cylinder
Hi Rex,

I was wondering if you could tell me how well the internal baffle is working , especially in terms of keeping dust out of the upper filter bag?

Kindest regards
 

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Discussion Starter · #16 ·
Making an Internal Thien Baffle for a HF Dust Collector

I was lucky enough to get the popular Harbor Freight 2 HP dust collector for Christmas. People have modified that thing in every way imaginable, so I found plenty of inspiration out there when planning what to do with mine. I decided to keep it fairly simple: a Thien baffle inside the dust collector's separator ring, to hopefully keep the dust in the bag and not in the filter. A lot of people have done this mod, but most of them don't post pictures because it is so simple. So I figured a quick pictorial of how I made mine might help someone in the future.

I used 1/4" MDF for the baffle. Many people use hardboard, but I have a really hard time finding stuff that is smooth on both sides. First I laid out the dimensions: 19" outer diameter with a 1.25" wide annular segment removed for 120 degrees of the circle.

Wood Rectangle Art Flooring Beige


I used my jigsaw to rough cut it out, making sure to cut outside the line.

Table Furniture Wood Flooring Floor


Next I rigged up a simple circle-cutting jig for my router table. I put my shop-vac hose close by to catch some of the MDF dust, but it still made a nasty mess.

Wood Table Flooring Composite material Automotive exterior


After cutting the drop slot with the jigsaw and router table (same way as before) and drilling 3 mounting holes, the baffle was complete.

Wood Table Floor Beige Art


To mount the baffle, I used 1" dowels and put hanger bolts in both ends. This way I could secure it with nuts and the baffle would be removable. The dowels need an angle on one end to mate with the dust collector ring, so I predrilled for the hanger bolt before cutting the angle.

Wood Floor Hardwood Flooring Wood stain


This allowed me to use the offcuts as angled washers.

Gas Plastic Auto part Electric blue Composite material


Fluid Gas Composite material Circle Plastic


Finally, I filled the center pivot hole in the baffle with epoxy and gave it a few coats of polyurethane. I did this so that hopefully the dust will stick to it a little less.

Table Furniture Tableware Wood Dishware


Wood Table Electronic instrument Audio equipment Musical instrument


In all, this baffle probably cost me about $15 for materials. In use, it definitely looks to be doing its job. Anyone who has this dust collector knows that the dust likes to swirl like a tornado in the bottom bag when it is turned on. This baffle has just about eliminated that swirling, so it should be keeping the filter bag cleaner. After using it for a few weeks, I noticed a few small leaks at the seam in the blower housing, so I sealed those with some caulk.

Automotive tire Fender Gas Bumper Thigh


I also put some weather stripping around the bottom of the collector ring where the lower bag seats. Those efforts seem to have sealed things up nicely.

Right now I just use this dust collector for my tablesaw, and it works very well. It definitely cuts down on the mess I make quite a bit. Eventually I will have a jointer and planer as well, and will hook it up to those. I'm sure it isn't the best dust collector out there by a long shot, but fits my needs nicely and cost about $170 including the baffle. When I get the money I do plan to add a Wynn cartridge filter, but for now I'm pleased with what I have. Thanks for reading!

Gas Building Machine Wood Cylinder
It's hard to say exactly how well it's working, because I still haven't upgraded to a canister filter. The big difference I do notice between my dust collector now and when I first got it is that there was a whirlwind of chips always swirling in the lower bag, and the baffle has stopped that. So I think the filter must be staying cleaner than it would have otherwise.
 

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Making an Internal Thien Baffle for a HF Dust Collector

I was lucky enough to get the popular Harbor Freight 2 HP dust collector for Christmas. People have modified that thing in every way imaginable, so I found plenty of inspiration out there when planning what to do with mine. I decided to keep it fairly simple: a Thien baffle inside the dust collector's separator ring, to hopefully keep the dust in the bag and not in the filter. A lot of people have done this mod, but most of them don't post pictures because it is so simple. So I figured a quick pictorial of how I made mine might help someone in the future.

I used 1/4" MDF for the baffle. Many people use hardboard, but I have a really hard time finding stuff that is smooth on both sides. First I laid out the dimensions: 19" outer diameter with a 1.25" wide annular segment removed for 120 degrees of the circle.

Wood Rectangle Art Flooring Beige


I used my jigsaw to rough cut it out, making sure to cut outside the line.

Table Furniture Wood Flooring Floor


Next I rigged up a simple circle-cutting jig for my router table. I put my shop-vac hose close by to catch some of the MDF dust, but it still made a nasty mess.

Wood Table Flooring Composite material Automotive exterior


After cutting the drop slot with the jigsaw and router table (same way as before) and drilling 3 mounting holes, the baffle was complete.

Wood Table Floor Beige Art


To mount the baffle, I used 1" dowels and put hanger bolts in both ends. This way I could secure it with nuts and the baffle would be removable. The dowels need an angle on one end to mate with the dust collector ring, so I predrilled for the hanger bolt before cutting the angle.

Wood Floor Hardwood Flooring Wood stain


This allowed me to use the offcuts as angled washers.

Gas Plastic Auto part Electric blue Composite material


Fluid Gas Composite material Circle Plastic


Finally, I filled the center pivot hole in the baffle with epoxy and gave it a few coats of polyurethane. I did this so that hopefully the dust will stick to it a little less.

Table Furniture Tableware Wood Dishware


Wood Table Electronic instrument Audio equipment Musical instrument


In all, this baffle probably cost me about $15 for materials. In use, it definitely looks to be doing its job. Anyone who has this dust collector knows that the dust likes to swirl like a tornado in the bottom bag when it is turned on. This baffle has just about eliminated that swirling, so it should be keeping the filter bag cleaner. After using it for a few weeks, I noticed a few small leaks at the seam in the blower housing, so I sealed those with some caulk.

Automotive tire Fender Gas Bumper Thigh


I also put some weather stripping around the bottom of the collector ring where the lower bag seats. Those efforts seem to have sealed things up nicely.

Right now I just use this dust collector for my tablesaw, and it works very well. It definitely cuts down on the mess I make quite a bit. Eventually I will have a jointer and planer as well, and will hook it up to those. I'm sure it isn't the best dust collector out there by a long shot, but fits my needs nicely and cost about $170 including the baffle. When I get the money I do plan to add a Wynn cartridge filter, but for now I'm pleased with what I have. Thanks for reading!

Gas Building Machine Wood Cylinder
Thank you so much for posting this. I've been looking at Thien baffle plans all morning after buying the same HF DC that you have. After looking at the $175.00 filters from Wynn Environmental I have decided it makes more sense for me to vent it to the outside than it does to spend more for a filter than I did for the DC.
 

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Making an Internal Thien Baffle for a HF Dust Collector

I was lucky enough to get the popular Harbor Freight 2 HP dust collector for Christmas. People have modified that thing in every way imaginable, so I found plenty of inspiration out there when planning what to do with mine. I decided to keep it fairly simple: a Thien baffle inside the dust collector's separator ring, to hopefully keep the dust in the bag and not in the filter. A lot of people have done this mod, but most of them don't post pictures because it is so simple. So I figured a quick pictorial of how I made mine might help someone in the future.

I used 1/4" MDF for the baffle. Many people use hardboard, but I have a really hard time finding stuff that is smooth on both sides. First I laid out the dimensions: 19" outer diameter with a 1.25" wide annular segment removed for 120 degrees of the circle.

Wood Rectangle Art Flooring Beige


I used my jigsaw to rough cut it out, making sure to cut outside the line.

Table Furniture Wood Flooring Floor


Next I rigged up a simple circle-cutting jig for my router table. I put my shop-vac hose close by to catch some of the MDF dust, but it still made a nasty mess.

Wood Table Flooring Composite material Automotive exterior


After cutting the drop slot with the jigsaw and router table (same way as before) and drilling 3 mounting holes, the baffle was complete.

Wood Table Floor Beige Art


To mount the baffle, I used 1" dowels and put hanger bolts in both ends. This way I could secure it with nuts and the baffle would be removable. The dowels need an angle on one end to mate with the dust collector ring, so I predrilled for the hanger bolt before cutting the angle.

Wood Floor Hardwood Flooring Wood stain


This allowed me to use the offcuts as angled washers.

Gas Plastic Auto part Electric blue Composite material


Fluid Gas Composite material Circle Plastic


Finally, I filled the center pivot hole in the baffle with epoxy and gave it a few coats of polyurethane. I did this so that hopefully the dust will stick to it a little less.

Table Furniture Tableware Wood Dishware


Wood Table Electronic instrument Audio equipment Musical instrument


In all, this baffle probably cost me about $15 for materials. In use, it definitely looks to be doing its job. Anyone who has this dust collector knows that the dust likes to swirl like a tornado in the bottom bag when it is turned on. This baffle has just about eliminated that swirling, so it should be keeping the filter bag cleaner. After using it for a few weeks, I noticed a few small leaks at the seam in the blower housing, so I sealed those with some caulk.

Automotive tire Fender Gas Bumper Thigh


I also put some weather stripping around the bottom of the collector ring where the lower bag seats. Those efforts seem to have sealed things up nicely.

Right now I just use this dust collector for my tablesaw, and it works very well. It definitely cuts down on the mess I make quite a bit. Eventually I will have a jointer and planer as well, and will hook it up to those. I'm sure it isn't the best dust collector out there by a long shot, but fits my needs nicely and cost about $170 including the baffle. When I get the money I do plan to add a Wynn cartridge filter, but for now I'm pleased with what I have. Thanks for reading!

Gas Building Machine Wood Cylinder
Rex

I seen what you done but it is not clicking for me on how it is working. Is the baffle higher than the inlet or lower? How is it keeping the dust from going into the bag?

Thanks
 

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Discussion Starter · #19 ·
Making an Internal Thien Baffle for a HF Dust Collector

I was lucky enough to get the popular Harbor Freight 2 HP dust collector for Christmas. People have modified that thing in every way imaginable, so I found plenty of inspiration out there when planning what to do with mine. I decided to keep it fairly simple: a Thien baffle inside the dust collector's separator ring, to hopefully keep the dust in the bag and not in the filter. A lot of people have done this mod, but most of them don't post pictures because it is so simple. So I figured a quick pictorial of how I made mine might help someone in the future.

I used 1/4" MDF for the baffle. Many people use hardboard, but I have a really hard time finding stuff that is smooth on both sides. First I laid out the dimensions: 19" outer diameter with a 1.25" wide annular segment removed for 120 degrees of the circle.



I used my jigsaw to rough cut it out, making sure to cut outside the line.



Next I rigged up a simple circle-cutting jig for my router table. I put my shop-vac hose close by to catch some of the MDF dust, but it still made a nasty mess.



After cutting the drop slot with the jigsaw and router table (same way as before) and drilling 3 mounting holes, the baffle was complete.



To mount the baffle, I used 1" dowels and put hanger bolts in both ends. This way I could secure it with nuts and the baffle would be removable. The dowels need an angle on one end to mate with the dust collector ring, so I predrilled for the hanger bolt before cutting the angle.

Wood Floor Hardwood Flooring Wood stain


This allowed me to use the offcuts as angled washers.

Gas Plastic Auto part Electric blue Composite material


Fluid Gas Composite material Circle Plastic


Finally, I filled the center pivot hole in the baffle with epoxy and gave it a few coats of polyurethane. I did this so that hopefully the dust will stick to it a little less.

Table Furniture Tableware Wood Dishware


Wood Table Electronic instrument Audio equipment Musical instrument


In all, this baffle probably cost me about $15 for materials. In use, it definitely looks to be doing its job. Anyone who has this dust collector knows that the dust likes to swirl like a tornado in the bottom bag when it is turned on. This baffle has just about eliminated that swirling, so it should be keeping the filter bag cleaner. After using it for a few weeks, I noticed a few small leaks at the seam in the blower housing, so I sealed those with some caulk.

Automotive tire Fender Gas Bumper Thigh


I also put some weather stripping around the bottom of the collector ring where the lower bag seats. Those efforts seem to have sealed things up nicely.

Right now I just use this dust collector for my tablesaw, and it works very well. It definitely cuts down on the mess I make quite a bit. Eventually I will have a jointer and planer as well, and will hook it up to those. I'm sure it isn't the best dust collector out there by a long shot, but fits my needs nicely and cost about $170 including the baffle. When I get the money I do plan to add a Wynn cartridge filter, but for now I'm pleased with what I have. Thanks for reading!

Gas Building Machine Wood Cylinder
Arlin - The baffle is lower than the inlet. The basic idea is that the baffle prevents dust and chips in the bottom bag from being scrubbed back up into the filter. With the baffle, what goes to the bottom stays at the bottom, which wouldn't always happen otherwise.
 

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Making an Internal Thien Baffle for a HF Dust Collector

I was lucky enough to get the popular Harbor Freight 2 HP dust collector for Christmas. People have modified that thing in every way imaginable, so I found plenty of inspiration out there when planning what to do with mine. I decided to keep it fairly simple: a Thien baffle inside the dust collector's separator ring, to hopefully keep the dust in the bag and not in the filter. A lot of people have done this mod, but most of them don't post pictures because it is so simple. So I figured a quick pictorial of how I made mine might help someone in the future.

I used 1/4" MDF for the baffle. Many people use hardboard, but I have a really hard time finding stuff that is smooth on both sides. First I laid out the dimensions: 19" outer diameter with a 1.25" wide annular segment removed for 120 degrees of the circle.

Wood Rectangle Art Flooring Beige


I used my jigsaw to rough cut it out, making sure to cut outside the line.

Table Furniture Wood Flooring Floor


Next I rigged up a simple circle-cutting jig for my router table. I put my shop-vac hose close by to catch some of the MDF dust, but it still made a nasty mess.

Wood Table Flooring Composite material Automotive exterior


After cutting the drop slot with the jigsaw and router table (same way as before) and drilling 3 mounting holes, the baffle was complete.

Wood Table Floor Beige Art


To mount the baffle, I used 1" dowels and put hanger bolts in both ends. This way I could secure it with nuts and the baffle would be removable. The dowels need an angle on one end to mate with the dust collector ring, so I predrilled for the hanger bolt before cutting the angle.

Wood Floor Hardwood Flooring Wood stain


This allowed me to use the offcuts as angled washers.

Gas Plastic Auto part Electric blue Composite material


Fluid Gas Composite material Circle Plastic


Finally, I filled the center pivot hole in the baffle with epoxy and gave it a few coats of polyurethane. I did this so that hopefully the dust will stick to it a little less.

Table Furniture Tableware Wood Dishware


Wood Table Electronic instrument Audio equipment Musical instrument


In all, this baffle probably cost me about $15 for materials. In use, it definitely looks to be doing its job. Anyone who has this dust collector knows that the dust likes to swirl like a tornado in the bottom bag when it is turned on. This baffle has just about eliminated that swirling, so it should be keeping the filter bag cleaner. After using it for a few weeks, I noticed a few small leaks at the seam in the blower housing, so I sealed those with some caulk.

Automotive tire Fender Gas Bumper Thigh


I also put some weather stripping around the bottom of the collector ring where the lower bag seats. Those efforts seem to have sealed things up nicely.

Right now I just use this dust collector for my tablesaw, and it works very well. It definitely cuts down on the mess I make quite a bit. Eventually I will have a jointer and planer as well, and will hook it up to those. I'm sure it isn't the best dust collector out there by a long shot, but fits my needs nicely and cost about $170 including the baffle. When I get the money I do plan to add a Wynn cartridge filter, but for now I'm pleased with what I have. Thanks for reading!

Gas Building Machine Wood Cylinder
Rex do you know if there is a difference in drop of pressure if I were to use the internal versus the external baffle?
I have an external barrel with the baffle already set up and now after reading yours here am wondering if I would be better with just the internal baffle. I have a Powermatic 3HP with double bags, 2 on each side of the impeller?
 

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