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Forum topic by HackFabrication posted 03-11-2019 04:33 PM 1176 views 1 time favorited 27 replies Add to Favorites Watch
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HackFabrication

106 posts in 44 days


03-11-2019 04:33 PM

First post to LJ (so if it’s in the wrong forum forgive and move). And it’s (of course) another HF dust collector upgrade post. I recently acquired my CraigsList dust collector. Previous owner only used it for one job: Removing attic insulation. It was ‘as new’. Got it for $100, then the upgrades started: Ditched the bag, got a Wynn filter.

Added the Rikon impeller:

Then modified the opening to 6” using a bellmouth flange from Air Handling Systems. The blower housing mod came with the usual anxieties of cutting a perfectly good part to make it a great part. But that’s what we do at Hack Fabrication.

Comparison with the original 5” HF flange:

A big shout out to Air Handling Systems for helping with the flange. The original one I purchased from them, wasn’t a true 6”. After a quick phone call, they fabricated one up with a 6” collar that is 100% welded to the bellmouth flange. Regular 6” steel duct pipe slips securely over it. As does 6” flex hose. The part was pricey (as was shipping), but the new and improved flange came free. Great customer service!

The new flange was installed with 1/8” poprivets using backer washers on the outside. This was to prevent any contact with the lager Rikon impeller. There is a healthy coat of silicon sealant between the flange and the housing. There was not interference with the impeller doing this.

This DC is now a beast with the new impeller. It will literally ‘suck’ your hand into the impeller if you aren’t careful!

Picked up a fiber 30 gallon barrel, and installed the Super Dust Deputy. The barrel has a fiber top, but I don’t see it flexing any more than a thin gauge metal top. Seems to be fine, and only time will tell.

For now, I plan to plumb the impeller housing to the SDD using 6” steel piping. I’m going to clamp it together, so it can be disassembled when ‘the time comes’.

Next is to come up with some design to make this somewhat mobile until I decide on a permanent mounting for it. Lots of good ideas here on LJ, and I’ve been ‘stealing’ a lot of them!

-- "In the end, it's all Hack..."


27 replies so far

View BoilerUp21's profile

BoilerUp21

125 posts in 1100 days


#1 posted 03-11-2019 05:23 PM

Looks like a nice setup. I did mine without upgrading the impeller or modifying the housing and saw nice improvements. Looks like yours went together nicely!

After spending the time and money to modify mine, I wish I would have just sucked it up and bought a factory system with the same features. When you figure:

~$150 HF dust collector
~$150 Super dust deputy
~$200 Wynn filter
~$100 impeller upgrade
~$30 drum or other

The average modification cost comes out to be $650… for a ~2HP machine (already had 1 HF motor go out on me in 6 months)... https://www.grizzly.com/products/Grizzly-2-HP-Portable-Cyclone-Dust-Collector/G0861

I sometimes wish i would have just spent the extra $300 for a manufactrued machine on casters and less time modifying a dust collector. Just my expierience, but for some people an extra $300 is not feasible.

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HackFabrication

106 posts in 44 days


#2 posted 03-11-2019 06:57 PM

Here’s a pic of the inside of the impeller housing plate with the bellmouth attached:

And another of the upgraded blower housing with the flange:

And yes, I can see where in the end it is probably more advantageous to just go buy a machine with all the ‘bells and whistles’.

But where’s the fun in that?.....

So far I’ve got:
$100 for the DC
$225 for the Wynn Filter
$180 for the SDD
$120 for the Rikon impeller
$30 for the fiber drum
$53 for the bellmouth flange
$40 in fittings
$70 in flex hose

I’m a bit under $830 total, with probably another $50-100 in extending the stock HF cart to hold the drum. A Mini Gorilla from Oneida is around $1350 + shipping.

More as I progress….

-- "In the end, it's all Hack..."

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HackFabrication

106 posts in 44 days


#3 posted 03-12-2019 12:28 PM

So I’m thinking about going this route next: Extending the stock HF mobile base with some angle iron and a 1/2” plywood platform. Then plumbing the impeller to the SDD with steel ducting.

Thoughts? I’ll add a single swiveling caster under the platform to handle any weight distribution issues.

-- "In the end, it's all Hack..."

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HackFabrication

106 posts in 44 days


#4 posted 03-14-2019 02:03 AM

So some progress is being made. I spent a hour or so Hack Fab’n up the extension out of 2” aluminum angle and 1/2 plywood:

I’ve got a large assortment of fasteners on hand, but unfortunately not 1/4” flat washers, so off to the local hardware for some tomorrow.

-- "In the end, it's all Hack..."

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HackFabrication

106 posts in 44 days


#5 posted 03-17-2019 07:14 PM

Some more progress on the DC. Got the base extension all bolted down:

Finished up the piping/duct work:

I’m using a simple 1/2” black iron pipe with a couple of floor flanges to support the ducting. Without support, the suction will compress the 6” flex pipe going into the SDD (and deflect/bend the ducting). The wood blocking is temporary while I wait for the glued up pieced to dry and get fitted. As it sets now, a lot of noise is being generated from the plastic bag under the filter ‘flapping around’. Everything else is reasonably quiet.

Most likely, I will use a couple of worm clamps to secure the short crossover duct to the vertical support pipe. Should keep it pretty stable, as I’ve done a couple of test runs without the pipe flange bolted to the base, and it works fine.

Quick anemometer reading at the 4” flex hose end, pegged the meter above 5700 fpm (speed over 67mph). Crude calculation is approximately 500 cfm at the end. I’ll take some better readings when everything is ‘bolted down’ and taped up with aluminum duct tape.

Ultimately, this will find a semi-permanent location in my basement shop, and get plumbed into 5” main duct work with 4” drops for machines.

-- "In the end, it's all Hack..."

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HackFabrication

106 posts in 44 days


#6 posted 03-20-2019 01:09 PM

Some more work:

Got the crossover duct brace fabricated and installed. I need to recess the clamps a bit further into the block, as the duct is resting on top of the screws and not the wood. Simple fix.

I picked up a pair of 3” casters at HF for the extension platform. It’s a bit tippy right now and will definitely need the support as the drum starts filling. Will get to installing them this week. Then I’ll take it all apart and pretty it up a bit with some boiled Linseed oil on the extension base, and black paint for the support rod pipe/flanges.

The discharge flange on the blower housing is leaking a lot of air, so that is going to need a good re-seal. And I plan on using aluminum duct tape on all the joints.

-- "In the end, it's all Hack..."

View fivecodys's profile

fivecodys

1389 posts in 1969 days


#7 posted 03-20-2019 03:54 PM

Hi Hack.
Yep, Tape up all the seams.
I am curious about the floor in your shop. Is that stamped concrete? It looks really cool!

-- When you leave your shop for the night, make sure you can always count to 10.

View HackFabrication's profile

HackFabrication

106 posts in 44 days


#8 posted 03-20-2019 06:28 PM


I am curious about the floor in your shop. Is that stamped concrete? It looks really cool

It’s cheap stickon vinyl tiles that the previous owner of my house laid down 40 years ago. He failed to complete the job, as there are many uncovered areas. They are a PITA to get up, so I haven’t removed them for something better.

-- "In the end, it's all Hack..."

View jimintx's profile

jimintx

910 posts in 1917 days


#9 posted 03-20-2019 08:34 PM

First, all the work shown here looks really good, and well done. I am sure it makes a nice system.

And then,

... After spending the time and money to modify mine, I wish I would have just sucked it up and bought a factory system with the same features. ...
- BoilerUp21

Every time I see one of these threads I read it, because I am so intrigued with the cult of HF-DC Mods. And I am with you on this one, Boilerup21.
Each time I read such a thread, I am pleased that I just waited till I felt I could afford it, and bought a nice system that worked on plug-in, and does a great job for me. (I do need to update and rework some DC piping in the shop, though.)

While I am intrigued with the mod group, I guess I simply prefer messing with woodworking over messing with machinery modification. But still, I do understand and I know there are plenty of folks that like to seriously mod their cars, or bicycles, or computers, or BBQs, ... and so on.

-- Jim, Houston, TX

View fivecodys's profile

fivecodys

1389 posts in 1969 days


#10 posted 03-20-2019 10:38 PM


I am curious about the floor in your shop. Is that stamped concrete? It looks really cool
It s cheap stickon vinyl tiles that the previous owner of my house laid down 40 years ago. He failed to complete the job, as there are many uncovered areas. They are a PITA to get up, so I haven t removed them for something better.

- HackFabrication

Well…..they look great in photos. :)

-- When you leave your shop for the night, make sure you can always count to 10.

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HackFabrication

106 posts in 44 days


#11 posted 03-20-2019 11:26 PM

First, all the work shown here looks really good, and well done. I am sure it makes a nice system.
-jimintx

Thanks! Hopefully it will fulfill it’s mission for me.

Each time I read such a thread, I am pleased that I just waited till I felt I could afford it, and bought a nice system that worked on plug-in, and does a great job for me.

But still, I do understand and I know there are plenty of folks that like to seriously mod their cars, or bicycles, or computers, or BBQs, ... and so on.
-jimintx


Yep. Economically, it’s a better idea to just yell ‘OUCH!’ once and be done with it. However, there’s no need to go all in from the get go. Most of the upgrades can be done over time, and thus spreading out the expense. For some people it’s easy to come up with $100 ‘here and there’, rather than save up $2k for a complete DC.

I could have dropped $1500 – $2000 for a complete system, and both economically and performance wise, would have been better served. But I’m that sorta guy that can’t seem to leave well enough alone. (I may start a thread about my Craftsman Tablesaw upgrade project. Which I refer to as ‘lipstick on a pig’)

And for me a lot of the time, it’s more about ‘the project’ than the results. This has been fun, and that’s what makes it important to me.

Well…..they look great in photos. :) – fivecodys

Yeah, and it does make it a bit easier to clean up the beer spills, cat vomit, and assorted other mini-disasters. Thanks!

-- "In the end, it's all Hack..."

View ibewjon's profile

ibewjon

284 posts in 3126 days


#12 posted 03-21-2019 02:20 AM

What is the rating of the Wynn filter? My jet filter is 2 micron, I would like something better.

View HackFabrication's profile

HackFabrication

106 posts in 44 days


#13 posted 03-22-2019 07:57 AM

The Wynn is rated at .5 microns. I believe you can purchase a Donaldson that’s also rated at .5 microns. The Donaldson is less expensive. But I don’t recall what the total sq ft of filtering space is with the Donaldson. The Wynn I’m using is the 35BA222NANO, it has a MERV rating of 15 and 222 sq ft of filtering. It is open at both ends (but comes with a steel cap), so if I ever decide to change how I mount the system, I have some flexibility.

-- "In the end, it's all Hack..."

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HackFabrication

106 posts in 44 days


#14 posted 03-22-2019 08:03 AM

Disassembled the unit last night and started to pretty it up a big. Fixed the cross over support clamp mount by recessing the clamps/screws a bit deeper:

Add the two casters, wiped the extension board down with boiled Linseed oil, and re-installed it onto the HF base:

Friday’s are short days for me, as I work a day shift, then go back in later for the midnight shift, so I won’t get to painting the support pipe/flanges until this weekend. Hopefully, I can get this all ‘back together’ by Sunday or Monday.

-- "In the end, it's all Hack..."

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HackFabrication

106 posts in 44 days


#15 posted 03-24-2019 09:20 PM

So, I just got the DC back assembled. Resealed the impeller outlet flange, used a bit of foil tape on the metal duct work, and wheeled it into it’s new ‘semi-permanent’ location:

Next step is to get a dedicated 20a circuit wired to it.

-- "In the end, it's all Hack..."

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