Dust Deputy Designs

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Forum topic by Kelly posted 12-11-2019 09:49 PM 1061 views 0 times favorited 24 replies Add to Favorites Watch
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3644 posts in 4106 days

12-11-2019 09:49 PM

Topic tags/keywords: dust deputy vacuum dust collection vacuum cart cyclone

I am curious as to why all the Dust Deputy carts with vacuums, like the one below, have the Deputy on top of, rather than under the vacuums. If it were underneath, the hose could be shortened, for example.

To better streamline my system (e.g., for my sand blast cabinet), I plan on drilling a hole in the bottom of the vacuum can, for a pipe sized to drop over the top Dust Deputy hole.

The pipe would run up to just a few inches from the top of the can Of course, the original hole would be plugged and everything sealed.

Any opinions?

24 replies so far

View ibewjon's profile


2535 posts in 3955 days

#1 posted 12-11-2019 10:02 PM

If I read you correctly, you want to move the suction hole to the bottom of the vacuum? If nothing collects in the bottom of the vacuum, it might work. Maybe put some pipe in the bottom hole to extend the suction above anything that might collect in the bottom.

View Kelly's profile


3644 posts in 4106 days

#2 posted 12-11-2019 10:04 PM

Somewhere in the edit, lost was the sentence saying the pipe would travel through the bottom to just a few inches from the top. Effectively, I would have just moved the intake port a little further inside the bin, but at the same distance off the bottom of it.

Nope, just went back to correct that, and it’s still there.

View Nick424's profile


153 posts in 1802 days

#3 posted 12-11-2019 10:05 PM

Would you not then have to lift all of that to get to the dust bucket? And with the vacuum on top it might tend to be top heavy.

View Kelly's profile


3644 posts in 4106 days

#4 posted 12-11-2019 10:12 PM

From my experience with such things, my Cart and wheels will offset moving the weight of the vac up, like a standard shop cyclone.

Keep in mind, you don’t have to have a sixteen gallon vac, since most of what’s collected lands in the cyclone bin. In fact, because of that, a full five gallon bucket could outweigh a vac, since very little lands in it.

When I switched to a DD from straight filters, the only problem I had was clogged filters due to the fines that get past, but I still saw runs between filter cleanings greatly improve.

I was able to drop back from a 16 gallon shop vac to a Rigid 7 gallon unit. Because the filter stayed clean longer, more power to keep efficiency up as long as possible became less important.

Setting the cyclone bin up to be supported by the cart would be a cake walk, and would allow me to pull the bin, just like on the bigger units.

View Kelly's profile


3644 posts in 4106 days

#5 posted 12-11-2019 10:23 PM

Several ways to skin the several cats being herded here. Just as the Gorilla has a flex hose between the bottom of the cyclone and the bin, the same could be done between the DD input and the pipe out of the bottom of the vac.

I could, also, allow enough flex in the support to allow releasing latches and just sliding the bucket out.

SIDE NOTE: I, definitely, will install a dust level view port on the cyclone bin, just like I did on my SDD I wheel out into the yard for pine cone duty. It works so well on the cart I can see through the big box clear bags [held in place by a cage] to monitor it’s fill level.

View Kelly's profile


3644 posts in 4106 days

#6 posted 12-16-2019 02:38 AM

I took a time off from my other distractions, grit my teeth, drilled a hole in the bottom of the new [little] shop vac the size of the pipe I’m using to connect it and the Dust Deputy.

Obviously, it would have been nice to have the pipe more toward the center of the can for better balance, but that wouldn’t work unless the can was much deeper.

I had heated and expanded the end of the black drain pipe to fit the top of the DD yesterday.

I pushed the pipe all the way in, until the flare that fits on the DD was against the bottom of the vacuum can, then hot glued it in place at the bottom and against the inside.

I laid a piece of scrap 1/8” plexi over the inside of the factory intake hole and heated it until it dropped against the interior contour of the vacuum can. After it cooled a bit, I applied hot glue to the area around the hole and pressed it in place (work fast).

All was set for the first firing. I placed the vac on the top of the can and dropped the flared end of the pipe over the top inlet of the DD. I hit the button and fed the beast a cup of dust. The suction felt strong and it ate everything I handed it fine.

The photo of the coarse filter suggests the DD grabbed almost everything, just sitting on a common paint bucket (to be improved).

My next question is, does it matter if the collection can under the cyclone is a box or a round container. If a box would work equally as well. I could make a deep drawer that could be gasketed and held in place by latches that applied pressure to insure the seal so critical to the efficient operation of a cyclone.

I apologize for the photos. Taking them was an after thought and I’m lucky to have taken them at all.

View sansoo22's profile


1748 posts in 817 days

#7 posted 12-16-2019 03:24 AM

Very interesting take on a cyclone cart. Mine is near identical to the one in your first post mainly because I already had a 10 gallon shop vac.

I don’t think the shape of the dust collection container matters much. From my understanding the venturi (spelling…sounds right at least) effect is happening inside the cyclone itself and the bucket is just catching whatever is pushed to the bottom.

If I had to build mine from scratch I would be trying out the smallest square shaped vac i could find with a square container for collection. Mainly because square shaped things are easy to find a home for in the shop then my current cart.

View Kelly's profile


3644 posts in 4106 days

#8 posted 12-16-2019 03:46 AM

This approach doesn’t make the over all package any smaller. However, as previously noted, it does cut out a lot of hose bends and, of course, the hose lifting all the debris up to the DD.

I was pleasantly surprised to learn just setting the vac down on the Dust Deputy worked. I haven’t down a smoke test using incense I keep around for that purpose. Even if it did leak, it wouldn’t affect the drop out efficiency of the cyclone like a leaking top to a collection bucket under one.

Anyway, that the vac is so easy to place on the cyclone makes emptying the lower bucket fairly simple. The top of the vac lifts off easily too for the rare times it needs to be emptied, or the filter needs cleaning.

I have zero doubt the design could be greatly improved with a differently configured vac, which would allow me to keep it more centered over the DD.

I didn’t choose a big vac because this one is going to be dedicated to my sandblast cabinet. We’ll see how that goes.

View Kelly's profile


3644 posts in 4106 days

#9 posted 12-16-2019 04:56 AM

Note this also puts the hose much lower, so pulling the unit around would reduce the chance of tipping a cart version.

View EarlS's profile


4629 posts in 3510 days

#10 posted 12-16-2019 01:31 PM

No reason that the dust bucket under the cyclone has to be round. I’m building a cart with the shop vac on one side and the DD on the other, with a plastic tote under it. Here’s a link to an example

The top of my cart will be 1.25” maple so I can use it as a work surface.

There might be an optimal height for the dust bucket. If you notice, the Oneida bucket appears to be a little taller than a normal 5 gal bucket. Still, I haven’t found anything that suggests someone is figuring it out.

-- Earl "I'm a pessamist - generally that increases the chance that things will turn out better than expected"

View sansoo22's profile


1748 posts in 817 days

#11 posted 12-16-2019 03:27 PM

I definitely saw the tipping possibility of the vertical cart design and improved upon that. Here is the base to my vertical cart.

At the time vertical made the most sense for me because I was in a one car shop. The unit never really needed to move around. The 2 hoses hooked together could reach all 4 corners plus some.

Now that I’m in a bigger 20×24 space I’m liking the idea of a smaller more compact unit. Please let us know how the smoke test goes if you do one. Between your test results and EarlS style collector I’ve got lots of ideas that require chopping up a shop vac to get the biggest motor in the smallest footprint.

View Kelly's profile


3644 posts in 4106 days

#12 posted 12-16-2019 05:32 PM

Sansoo22, I’m with you on the chopping up a vac thing. I’ve already been eyeballing the motor and such and suspect I could reduce the tank to 8” to 10” in diameter plastic pipe.

I see no reason a filter could not be hung out the side, rather than straight down, to allow a small vac collection can.

This would also mean a better filter could be used, if the unit was, as such thing usually go, exhausted in the shop. Mine is, as I’ve already said, for a blaster and will be exhausted outside, so HEPA isn’t as important.

Of course, all this might also mean being able to use a more powerful vac too.

If either of of get to it, I suggest we call it something with Rube Goldberg mixed into the name.

View Kelly's profile


3644 posts in 4106 days

#13 posted 12-16-2019 05:37 PM

Earl S, his drop box was something like I was thinking.

My big cyclone has a plastic barrel with a piece of old countertop for its lid-cyclone mount. It uses truck hood hold downs to pull it tight against door gasket materials (smoke test shows no leaks).

Since this will be wall mount and only has to collect dust, I’m thinking of switching the bucket to some 10” diameter pipe for under the cyclone. I’d add the view port, like my big drum has (above) and toggles or some other means of dropping the bottom out for emptying.

View gtrgeo's profile


168 posts in 1592 days

#14 posted 12-16-2019 05:49 PM

Interesting experiment. I have a small shop vac and dust deputy which are bolted together as suggested in the manual with some small casters on the bucket. While it is “mobile”, moving it is a pain. I have contemplated going to a stacked setup due to the reduced footprint and possibly better mobility by using better casters under the assembly but have concerns about stability without again having the larger footprint.

Overall I struggle to get over the added bulk in the assembly caused by the vacuum canister which is essentially unnecessary as most debris ends up in the bucket under the Dust Deputy. This becomes more of a problem when using the more powerful vacs as they seem to always come on 14-16 gal canisters.

Thinking like you would with building a larger cyclone I have wondered why we couldn’t just use a blower from one of the shop vacs with removable motor. Then configure a shop vac hepa filter on the outlet. It would take some work to adapt the pieces together but would eliminate the vacuum canister. The closest I have seen to this was someone who replaced the vac canister with a plywood box.


View Lazyman's profile


7436 posts in 2550 days

#15 posted 12-16-2019 05:53 PM

BTW, you are going to want a better filter than shown above. I recommend the Gore Cleanstream shop vac filters, assuming that PC vacuum uses one of the standard sizes. Probably as close to HEPA as you can get on a cheap shop vac, cleanable, only a little more expensive than disposables and last for years.

-- Nathan, TX -- Hire the lazy man. He may not do as much work but that's because he will find a better way.

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