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The
original 1hp dust collector |
 My dust collection
adventure began with a single stage 1 HP Reliant brand from Trendlines
in December of 1995. As the hobby, the tool collection, and the shop
area grew (now 15’x27’ – about 400 square feet), this
did not suffice in terms of suction or in terms of safety. I was spending
more and more time exposed to the dust that flows right through the
cheap filter bags (see Bill’s
site for more information on this).
Initially, I had
planned to use the old blower and motor in conjunction with a drop box
in the shop. Then, I pondered the possibility of exhausting the dust
collector outside and not worrying about filtering. This, however, is
known to create a very dangerous situation, as fumes from the furnace
and water heater would flow directly into the shop, particularly in
the winter when I can’t comfortably open a window to help replace
the air in the shop.
So, it was clear
to me that I needed to set a system up that was completely contained
within the shop. It was also clear that, because of their small size,
the 1 HP motor and 10” diameter fan were not going to do me any
good for the kind of system I envisioned (see Bill’s
site for more information on these size requirements as well).
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Thanks
to Glen for this graphic |
Bill Pentz convinced
me to construct a cyclone, as intimidating as that sounded. This website
thoroughly explains how a cyclone separator, in conjunction with a home-made
blower and filter set-up, effectively collects woodshop dust. However,
for those unfamiliar with this topic, the diagram at the side should
help you understand exactly what happens in this system. The blower,
mounted on top of the cyclone, consists of a motor, fan, inlet and outlet.
As the motor turns the fan, suction is created at the inlet, which is
connected to the cyclone outlet pipe (4). Dust and chips from the network
of ducts throughout the shop enter through the cyclone inlet (1) and
are forced to circulate around and around in the upper cylinder of the
cyclone. As the air approaches the funnel shaped cone of the cyclone
(2), dust and chips continue to be spun against the sides and eventually
settle down in to the collection bin (3). The remaining air and very
fine dust are sucked out of the cyclone through the cyclone outlet pipe
(4), into the blower, and blown out the blower outlet toward a filter.
This filter captures the very fine dust (which are now known carcinogens),
and allows perfectly clean air to be exhausted back into the shop. Many
websites go into greater detail on this topic.
A month and a half
later my cyclone was complete, the shop was re-organized, and the ducting
was being finalized. This is the story of that process. Hopefully, it
can help others decide what they want to do with their dust collection
system. I know that I would not have endeavored upon this project if
I hadn’t known that there were many others who had successfully
completed the project and were available to help me along the way. And
help me they did! Through dozens and dozens of emails with fellow woodworkers,
I was able to put together a powerful dust collection system that makes
my shop cleaner and my household a safer place to be. Hopefully, this
information can help the next woodworker who has these same goals in
mind.
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