Customized Shop Dust Collection System

Customized Dust Collection System from Scrap materials.

Hi all, some of my Instructables are clearly thought and planned out. Others not so much, more make it up as I go. This Instructable is a bit of both. It’s something I’ve been wanting to do for sometime, especially more so as I’ve added more shop tools to my confined work area. Rather than go through my thought process on this I’ll just break it down on my stages of progress. I’m pretty big on reusing scraps and left over unused materials. That is the case for the majority of this Instructable, with one exception.

My day job uses large format proofing printers such as Epson & Hewlett Packard. The rolls of paper used in these have cardboard tubes that were being thrown away constantly. I saw potential for these and have used them for many uses.

1. Throw away Cardboard Tubing
2. Plywood
3. Wood Screws
4. Left Over PVC Connectors
5. 3D Printed Gates
6. Duct Tape
7. Shop Vac Hose
8. Wood Glue
9. Hot Glue / Glue Gun
10. Various Clamps
11. Bandsaw (or hacksaw to manually cut tubes)

I guess my first progress was when I set about to improve my shop vac. My Shop Vac is a small one and I was constantly emptying it which is a messy process. Not to mention having to replace the costly filters. So I made my own separator dust collection addition to the vac using the paper tubes and a bucket. I'm not going to explain how this was done in that there are a slew of YouTube videos out there on the process. It worked great.

But I quickly realized the two separate parts were really clumsy to have to move around. So I used more tubes to create a stacked unit. I had a left over round plywood circles (another work throw away from huge paperboard cores) which was perfect to hold the top bucket separator. I used 4 tubes which actually fit the base of the original shop vac perfect as well.

As it turns out the plastic tube core holders that fit the printers spindle were useful to mount the tubes to the underside of plywood with screws. I attached the bottom of the tubes to the shop vac base with screws as well. I cut a large enough hole in the top of the plywood to set the upper bucket in. I routed down the edges and my initial set up was good but the tubes at full length were a bit too tall. So took measurements to down size them, making sure there is enough clearance from the shop vac exhaust.

Once I was happy with the configuration I painted the tubes and the plywood black. Assembled it back togehter and the setup has proven very usable. And since its on wheels it easily moves anywhere I need it in the shop.

My first shot for helping control dust collection(aside from the shop vac improvements) was working on my grandfathers homemade belt sander (the history on it is pretty wild, the motor its using is a Packard from early 1900s). My grandfather worked at Studebakers Car Maker as a machinist. It got to where it would refuse to operate in cold weather. Go figure, I'm like what a piece of crap, something over 100 years old and dosen't work all the time?? I ended up taking it all apart and cleaned out a 100 years of sawdust and now it runs like a champ.

Originally the base below the sanding surface was opened. This device was one of the biggest dust makers in my shop. So I boxed in the bottom. I put and exhaust port on the side to hook the shop vac hose up to. The black connector is actually the same plastic piece I used to mount the tubes in my Shop Vac upgrade. Hooking up my shop vac hose to it worked great and cut dust down significantly. My shop vac configuration proved very helpful just simply hooking up my hose to what ever device I’d be using.

The other device I have that is a major dust maker is my band saw. You can see my first attempt was a make shift cardboard duct tape concoction. It worked but as you can sit a bit unsightly and not as efficient as it could be. I'm still working on getting a better connector. So I came up with some what better solution targeting just the area where the cut is made, a vast improvement. I'm still going to tinker with it and when I get my final solution I'll be sure to post an update.

The Belt/Disc Sander also was a major dust maker. I found online a 3D printable adapter for a Harbor Freight Central Machinery Belt/Disc Sander and had one made. It works pretty good. I'd post the file but It's been so long ago that I got it I can't remember if its copyrighted.

But I've found a similar one selling on EBay. Just search for: Vac Attachment Sawdust Collector for Central Machinery Belt & Disk Sander Shop

It says: If you already own a 3D printer, the .STL files are available for FREE download at Thingiverse.com/thing:1916830. Not sure if its still there.

After working with my plug and play set up, for well over a year if not longer, I decided I need to implement a true (my own interpretation at least) dust collection system.

I took to watching YouTube videos on dust collection. I realized I could emulate a similar setup again using my left over cardboard tubes. My recent Spindle sander purchase made me set about creating a layout for how my tubing should be positioned around the shop. I had some left PVC connectors from a home plumbing project that I never bothered to return for refund. As it turned out they matched up perfect with my scrap tubes.

Now my brain was really perking. I first devised a layout for positioning my devises around the shop. Then used the tubes and PVC connectors around the back of my countertop to each device. I cut portions of the tubes to size to run between devices and using duct tape I connected the PVC connectors in place. I did the first four devices on my counter top. With a shop vac hose connection point positioned right near the shop vac itself. Then working around the back of the each device adding PVC ports.

I'll break down how I worked up connections to each devise.

1 Belt/Disc Sander - The existing 3D printed exhaust port that I printed was a simple hook up placing the hose to it and the PVC connection. I did have to hunt for some small 3/4" inch tubing to connect the disc exhaust to the 3D adapter.

2 Spindle Sander - Had a exhaust port a the top back already built so again and easy hose clamped to it and fed in the PVC connection.

3 My Grandfathers Homemade Belt Sander - I had already created the box with a exhaust port out the side but decided to retool and put the port out the back at the bottom. This way dust would be less likely to collect in the bottom like it was doing and I'd have to clean it out occasionally. With port out the back repurposing the black tube core plug and another hose clamp worked joining the hose to the box then the other end of the hose to the PVC connection.

4 Scroll Saw - It has a smaller exhaust port(in the front no less?), so luckily I had a couple of left over hoses from my broken Dirt Devil vacuum that I never threw away. With some coaxing it fit pretty well to the front of the saw. I had an shop vac adapter that I used to connect the hose to the PVC and it worked pretty well too. 

After having them all hooked up then plugging the vacuum hose into the system the shop vac was pulling I’d say 75% of the dust from each device. That is then when I realized I need to create blast gates for each device to stop the dead flow from devices not being used.

On to BLAST GATE CREATION

First lets cover my moderate successes and out right fails.

I researched several variations on blast gates and just in case your not familiar with the concept of blast gates here is a brief explanation. Blast gates are placed on each individual devices with an open closed slide to shut off or open air flow to said device. 

My first design all out of MDF. It works but is a bit clunky as its heavy. I’ll probably still use it at some point. The slide on it not very elegant.

I then tried to be creative with a more elegant design (see my digital designs) but there proved to be a major flaw with it. Which is a shame because I really love the small size and simple operation. See if you can figure out what that flaw is based on my pictures. I may get a flash of inspiration and figure out a way to make it work. If I do I'll be sure to share.

My final gate design combination new tech and old mixed together. After my failed attempts I came up with what I think is a good solution. I designed a 3D printed gate with tube and slide ports (STL file below). I had several printed. A few 3D prints failed but I made use of the failed portions by cutting in half and super gluing together. As you can see it turned out pretty good.

I cut down small portions of tubes (about 4" which is enough to nest the hose into) and hot glued them into the circular gate holes. One tube for each side. Note: before gluing in place I slid a piece of 1/8" plywood in the slide hole so the tube would not intrude on the slide area.

I then made slides out of scrap 1/8” plywood. Measuring the slide hole and width of the gate, doubling the length, I drilled a corresponding hole in the slide to match the size of the tube opening (this hole would be the open position).

I added stops for each open end. After my initial test of the first prototype I mass produced the others I needed. For the time being the stops are only at the open ends, but will eventually I'll add stops to the closed end as well. This will help prevent pulling the slide out entirely. If you notice I rounded off the corners of the stops making them look a bit nicer.

Check out the videos on the the gates slide operation.

With the Gates all created I went about installing in place at each device. I cut portions of shop vac hose to connect the devices to the gates and to the PVC tubing. So it breaks down like this:

Device > Tube > Hose > Tube > Blast Gate < Tube < Hose < PVC < Tube to Vac

Duct taping the tubing to PVC connectors & to the hoses to blast gates to hose to device.

The video here starts off with what will eventually be the Optional gate that I'll use to connect to my miter saw, or the router table as needed. You can see the saw dust is drawn in pretty good. But if you watch closely as it pans around I neglected to close the gate on the scroll saw, so it'll work much better when all gates are closed (Face Palm)

Eventually I'll extend tubing and add two more gates 1 for my Band Saw which works fine for now using my modified collection port, 2 for my Drill press. Which will need its own unique hose port configuration. I'll be sure to share its creation as an update eventually.

In Conclusion I'm really proud of myself making this work. And I guess that's the point making something that works for your personal situation is what its all about. And the great thing the money I spent was early on for the Shop Vac separator top. I got for about $30 at the time(now its about $40-$50. So if you don't count the cost of duct tape, screws, and PVC connectors I already had not a bad overall cost for a dust collection system.

OK the great things about these tubes I’ve found numerous ways to use them. Granted all tubes vary in sizes and shapes. But I've found them to be very versatile for many things. Check out some of my implemented ideas.

• Obviously the Shop Vac upgrade
• Organizers for tools, pens, zip ties
• Tool Storage and a unique way to store my bungee cords