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4” to 2-1/2” DC system modification

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Forum topic by Wood_Scraps posted 05-12-2021 07:28 AM 282 views 0 times favorited 10 replies Add to Favorites Watch
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Wood_Scraps

163 posts in 142 days


05-12-2021 07:28 AM

Picked up a Wen 660 CFM dust collector. It’s a 4” system, but my TS has a 2-1/2” dust port. Easy enough to add a reducer. But, I’ve seen many advocate for trying to avoid reducing the system’s airflow.

So, I was thinking that maybe I can “port” the reducer. Basically just drill a few 1/2” holes in the collar of the coupler to effectively maintain roughly 4” of airflow.

Thoughts? Anyone done something similar or have a better solution? Am I making a mountain out of a molehill?

Eventually I want to 3D print a over the blade DC hood, splitting the DC between the bottom port and blade hood. So, at that point it’ll be a self correcting solution. But, wondering if the ported coupler is worth doing in the interim.

For reference, below is the reducer I’m using. Would drill the holes in the ledge portion.

Thanks!


10 replies so far

View tvrgeek's profile

tvrgeek

1944 posts in 2772 days


#1 posted 05-12-2021 09:50 AM

You picked up a chip collector and high power dust atomizer that will insure the fine dust that is very bad for your lungs gets fully spready in the air. So, a N95 mask of full half face respirator is a must. Or, will work fine to save some cleanup if working outside in a breeze. Probably will work great on small jointers and planers that make shavings, not dust.

Hook it up and see how it does on the chips. Some have had pretty good luck with the small blade shroud port. Some done better with a vacuum on that port. ( Fronted by a small cyclone so not to fill bags as fast)

But in any case, I stress it is NOT a dust collector. Real dust collectors are large, expensive, and will have MERV-15 or HEPA filters on them as it is the sub-micron dust that is so dangerous to your lungs.

View Fred Hargis's profile

Fred Hargis

7028 posts in 3616 days


#2 posted 05-12-2021 11:55 AM

What he said^^^^^^, harsh words but true. That unit will have marginal performance and while your venting plan will help insure some airflow, it will happen past the point of pickup…so you won’t be improving the dust collection in any way.

-- Our village hasn't lost it's idiot, he was elected to congress.

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Wood_Scraps

163 posts in 142 days


#3 posted 05-12-2021 01:48 PM

I forgot to mention I’m venting outside so I don’t have to worry about high end filters. Also have a cyclone. And, have long owned and use a 3m respirator.

Edit: And also plan to build a air filtration unit for the ceiling.

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tvrgeek

1944 posts in 2772 days


#4 posted 05-12-2021 03:11 PM

Yes, harsh, but we are talking about health. I bought my drill press from an ESTATE from a woodworker who did not pay enough attention to the fine dust. Emphysema.

So, back to the table saw. for the single shroud port, some have suggested a vac works better. I enclosed my contractor saw and used both the shroud and the box. I now run a Harvey which does not have a shroud, but the ClearView and 6 inch suck like all get out!

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Fred Hargis

7028 posts in 3616 days


#5 posted 05-12-2021 03:16 PM

The cyclone will just impair the air flow, they are a huge drag on a system. Venting out should help, but that DC is no more a 660 CFM system than the 6.5 HP your shop vac has. The air filter is good, but remember by the time it catches the dust, it’s already in your lungs. The respirator is a good plan.

-- Our village hasn't lost it's idiot, he was elected to congress.

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AlanWS

141 posts in 4681 days


#6 posted 05-12-2021 04:02 PM

As you note, venting outside takes care of the dust with less back pressure, so the DC will function better. While a cyclone costs some flow, for most it’s worth it.

I would not add a permanent leak, which will decrease the effectiveness of dust collection. The reason retaining full flow in a 4” duct is helpful is that the lower flow with a 2.5” inlet may allow the dust to settle out in the ducts. As they fill, the air speeds up to eventually move it, but that can put so much in one spot it can clog the duct. As long as your small hose does not put too much dust in at once, you can just flush the system periodically by opening a blastgate or pulling off the hose for a while.

If you restrict the flow, you are decreasing the load on the DC motor, so there’s no problem with that, assuming it’s an induction motor not a universal motor as in a shopvac.

-- Alan in Wisconsin

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Wood_Scraps

163 posts in 142 days


#7 posted 05-12-2021 04:34 PM



Yes, harsh, but we are talking about health. I bought my drill press from an ESTATE from a woodworker who did not pay enough attention to the fine dust. Emphysema.

So, back to the table saw. for the single shroud port, some have suggested a vac works better. I enclosed my contractor saw and used both the shroud and the box. I now run a Harvey which does not have a shroud, but the ClearView and 6 inch suck like all get out!

- tvrgeek

It’s worth the callout. Can’t expect you to have known that I already use a respirator. And any newbies who stumble across the thread will benefit from that addition.

As far as a vac, that may be true for some saws. For this saw, and with this particular DC, users have established that without question collection is improved over a shop vac.

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Wood_Scraps

163 posts in 142 days


#8 posted 05-12-2021 04:45 PM



The cyclone will just impair the air flow, they are a huge drag on a system. Venting out should help, but that DC is no more a 660 CFM system than the 6.5 HP your shop vac has. The air filter is good, but remember by the time it catches the dust, it s already in your lungs. The respirator is a good plan.

- Fred Hargis

The air filter will not be a replacement/reason for tossing the 3m mask aside. Instead, my primary aim is that it’ll clean the air after I’m done working and have left the garage.

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Wood_Scraps

163 posts in 142 days


#9 posted 05-12-2021 04:48 PM



As you note, venting outside takes care of the dust with less back pressure, so the DC will function better. While a cyclone costs some flow, for most it s worth it.

I would not add a permanent leak, which will decrease the effectiveness of dust collection. The reason retaining full flow in a 4” duct is helpful is that the lower flow with a 2.5” inlet may allow the dust to settle out in the ducts. As they fill, the air speeds up to eventually move it, but that can put so much in one spot it can clog the duct. As long as your small hose does not put too much dust in at once, you can just flush the system periodically by opening a blastgate or pulling off the hose for a while.

If you restrict the flow, you are decreasing the load on the DC motor, so there s no problem with that, assuming it s an induction motor not a universal motor as in a shopvac.

- AlanWS

Thanks for the breakdown on reducing flow and insight into the idea of porting the coupler.

Venting outside is definitely a twofold solution. One, to eliminate the need for high end filters on the outflow. Two, to maximize overall performance.

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Wood_Scraps

163 posts in 142 days


#10 posted 05-17-2021 01:24 AM

Update

Ran the Wen through its paces yesterday. Ripped some pine and oak. Significant improvement over the shop vac. Which would leave quite a bit of sawdust on both the table and floor.

Even though I’ve not yet split the Wen DC between the port and blade guard, it leaves almost nothing on the table. Small amount of the floor (maybe half a shot glass worth, lol) But that’s likely because the blade shroud of the port has a couple small gaps. Figure once I seal those off it’ll be next to nothing on the floor.

Cyclone worked perfectly as well. No idea how much made it through to the exhaust. I’d imagine it was minimal. But, since I’m venting outside, the actual output is meaningless to me.

Worth every penny.

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