Wood Magazine Cyclone Dust Collector Plan,Curved Reception Desk Construction,Woodworking Plans For Toys Free,Modern Bunk Beds With Stairs - Videos Download

21.10.2014
The only thing I've found is if I leave a blast gate open, air will constantly siphon thru the cyclone and ductwork, drawing heat out of the shop.
Todd After looking at your cyclone, It looks to me that your infeed tube should be at the back.
Wood engraving service london, woodworking blanks turning,built in cabinet ideas for family room. My early woodworking and medical engineering work eventually taught me to minimize fine dust exposure, especially when working toxic woods.
Unlike most my dust collection started with my getting rid of the dust cloud that filled our family home construction cabinet shop. At home my dust collection went through the normal foolish progression where all worked poorly.
We loved that upscale lifestyle so much that when our family grew we upgraded to a much larger home in the same neighborhood that had an oversized three-car garage that let me dedicate one whole garage bay to my woodworking. Tired of the dust that settled overnight ruining finishes, I upgraded both of my Cincinnati Fan dust collectors and my ShopSmith Dust collector with large polyester fine filter bags. Worse, my finishes were still getting ruined from overnight dust settling, so I built an air cleaner using an old water cooler fitted with fine HVAC filters. The replacement commercial ceiling mounted air cleaner did a much better job protecting my finishes, but my new particle counter showed just like the so called fine filters on my shop vacuums and dust collectors my air cleaner filter passed the fine dust right through so it also was a dust pump that stirred up and kept the unhealthiest fine invisible dust circulating.
My area has many local sawmills and the cost to buy my lumber from them rough cut is about half the price for finished lumber, so I did my own planning and surface sanding. Frustrated at how little air my ShopNotes cyclone moved and how poorly it separated, I built a new cyclone based on the Wood Magazine cyclone plans. Instead of getting good advice that would help solve these problems, all the Internet woodworking forums were filled with ugly dust collection fights.
Top Rated: I really just wanted to buy a used smaller commercial cyclone, but was very frustrated as none were available locally that would fit in my garage based shop with its eight foot tall ceiling. Installation: In September 1999 I installed that "best" magazine rated cyclone following the vendor designed and supplied ducting diagram for my shop and used the vendor recommended upgraded fine filter.
Bad Cyclone Design: This cyclone had all of the same problems my prior cyclones did before I upgraded them except the metal was heavy enough it did not deform when I turned on my blower. Bad Airflow: The airflow testing showed my expensive magazine top rated cyclone moved less than half its advertized air volume and its actual flow was far less than my dust collector it replaced. Poor Collection: Although the vendor promised in writing enough airflow to provide good fine dust collection from three large and one small tool working at once, its working airflow barely collected half as well as my home built cyclones when just collecting from a single tool.
Poor Separation: Particle testing showed that this expensive top rated cyclone separated no better than a $25 trashcan separator lid. Duct Plugging: This system used tiny down drop ducts that that so restricted the airflow both the larger vertical ducting runs and larger main ducting run were left without the air volume or speed to keep the dust moving.
Blown Joints: These plugs and ducting piles also created a constant frustration because when airflow was restored so much material went shooting down the ducts it created lots of noise and hit the duct joints so hard they blew apart filling my shop with debris and dust. Vendor Support: This cyclone proved so worthless when using my planner and big sander, that I had to go back to using my old dust collector. Decision Time: Constantly having to clean the filter, fix blown apart ducts, and clear the cone and duct plugging left me and shop covered in the dust this system was advertized to collect, plus left me spending almost as much time on my cyclone as I spent doing woodworking. Failure: Additionally, this cyclone worked so poorly I decided to junk it right after finishing my Christmas projects.
I am very stubborn and did not want to give up either my three generations of tools or my favorite hobby in spite of my doctors saying no more woodworking until I did not have such strong allergic reactions. My friend Dizzy lives nearby, is a spectacular craftsman who works metal and wood, plus a very inventive engineer who had already come up with many of his own solutions for making the Wood Magazine cyclone workable.
Unlike most, my engineering background allowed me to do some serious testing then come up with my own far better fine dust separating cyclone design. I did put a piece of mesh wire in between the coupling and the pipe before assembly, I didn't want to be cleaning up Sparrow parts from inside the cyclone unit.
I made this splitter and zero clearance insert after attending a woodworking class taught by Kelley Mahler.
Here are a couple of other views of the dust collection ducting, the sliding table and the outfeed bench. I found his plans to be good, he has a spreadsheet you can download from his site on the Cyclone Plan page Section L. My father apprenticed to a fine woodworker who specialized in cabinets and trim for very expensive homes.
I started with a small shop vacuum, a larger vacuum, a ShopSmith small dust collector, and a larger dust collector. This left me a permanent place to put my dust collector, large air compressor and largest tools, but I still needed most on wheels.
These bags clogged constantly because woodworking makes too much fine filter clogging dust. This saved lots of money on the mostly red oak and walnut projects I liked to make, but left me feeling like I spent more time emptying the too heavy 55-gallon drums under my dust collectors than doing woodworking. It turned out that plan created an almost identical cyclone to the ShopNotes unit, so it had identical separation and plugging problems, plus had even more problems. Regardless of using a home built or purchased cyclone, it seemed all who did little to no woodworking loved their cyclones and those of us who made a lot of dust and chips hated ours. Realizing that the problem was our traditional cyclones had way too much internal turbulence, I then kept tweaking to reduce that internal turbulence. He said he contacted that same top magazine rated cyclone firm, was assured that their standard cyclone moved more than enough air for his two and sometimes three person shop with all working at the same time. Just like my prior two cyclones it separated so poorly it quickly plugged my fine filter and its cone plugged every time I used my planner, my shaper or collected lots of chips. Although advertised as a better than 2-micron filter, when tested with calibrated test particles this filter freely passed 100% of the invisible 10-micron and smaller invisible dust particles known to cause the most health damage. I discovered my vendor used and still uses a free computer ducting design program designed for larger shops that do not use blast gates and instead collect from all machines running at the same time. This cyclone worked so poorly and the vendor had no integrity, so I decided to junk it right after finishing my Christmas projects and replace it with a used commercial Donaldson-Torit cyclone similar to what I installed at the university and my family shops.
He built one of the Wood Magazine cyclones, but ignored the too thin metal and made a true work of art.
He did a little research and discovered that the way professional blower firms compensate for the overhead of a cyclone is to use oversized blower impellers.
I oversaw the testing of every major brand and size of small shop cyclone during 2007 and 2008 and since 2000 have overseen four different magazine tests on dust collectors and cyclones. It is made from a offset HVAC register boot with 2 pieces of scrap sheetmetal attached on the sides to make a half circle for better collection. I roll it over by the router station to use it so I can hook up to the dust collection system. When we upgraded the family cabinet shop to a commercial dust collection system I claimed a 2 hp Cincinnati Fan dust collector made up of a big blower that sat on a roll around 55 gallon drum.
That inspired me to buy a new dust collector that was supposed to eliminate the clogging problem and still provide good fine filtering. This cyclone was based on a 1963 public domain cyclone design for wood dust collection given out for free by the New York State Department of Labor. I ended up changing the inlet size, added an air directing ring to further reduce turbulence, increased the outlet size, changed the cone angle, and increased the dust chute size. Even with all my dust collection efforts, my cyclone's poor airflow provided terrible collection making for frequent large messes to clean up.


I contacted the magazine top rated cyclone supplier and got from them a full quote including ducting design with all the parts detail, but was hesitant to pull the trigger. He talked to their chief engineer and said that fellow not understand either woodworking or dust collection.
The ducting design was horrid and required me to redo most of it because their design left off all kinds of required parts to implement their plan. Careful measurement showed it was exactly the same cyclone except for a slightly larger center outlet tube that held its internal filter.
This tiny cartridge that fit inside the cyclone outlet was way too small so not only plugged constantly, the heavy cleaning quickly ruined this cartridge. As a result, most of the heavier dust and chips simply piled up in the larger horizontal duct runs then these piles grew in length into huge long piles.
It clearly did not collect well, plugged its cone constantly, plugged its filter every twenty minutes, and it ruined its first filter within a few days. Instead before I could get rid of this piece of junk it landed me in the hospital, left me unable to do woodworking, and nearly killed me. I came up with a better solution designing a cyclone that moves more air with less power and provides more than six times better fine dust separation which is what we need to protect our fine filters that respiratory physicians recommend. My goal was not financial gain or vindictiveness against that top magazine rated vendor whose advertizing lies so harmed my health. Rather than admit in these tests that the true measure of a cyclone separator is how well it separates, these vendor dominated magazine tests ignored cyclone separation and working airflow to instead focus on maximum airflows.
Although he preferred to do his woodworking with hand tools, he equipped this cabinet operation with the best in commercial quality tools. I also was dragging a very long flexible dust collection hose from my dust collector and having to change it to each different tool I used. The fan much more quickly got rid of both the larger airborne particles that ruin finishes and the buildup of fine dust that ruins our lungs. Instead of following that 1963 design someone severely changed the dust chute that connects to the dust bin down from 6" to only 4" so it would work with the 4" ducting that most small shop stationary tools use. All serious users had problems with poor airflow, bad collection, cone plugging, and filter cleaning. Most of those who bought these same top magazine rated cyclone systems swore by them, but I had been hearing some bad things as well. He bought the works including their recommended cyclone, all the ducting to plumb his pretty good sized shop, and even a batch of their recommended upgraded fine cartridge filters. Almost all of his machines had the typical 4" sized dust collection ports and hood attachments, but this cyclone would not even provide good collection when pulling from just one of these tools working at a time. In other words, I got the same problems as before on a cyclone I could not easily change to add my prior improvements. It took me longer to take apart the cyclone to clean this filter than it took to load the filter back up. Larry went with a properly proportioned woodworking cyclone with the right sized cone and dust chute so his cyclones did not plug every time we used a planner. I helped this firm by redesigning their blowers, cyclone cone, dust chute, cyclone inlet, cyclone outlet, neutral vane, filter stack, filter cleanout, and revised their ducting design program. A couple of holes drilled in the insert provide a finger hold to get it out and also help the dust collection.
I installed 4" PVC ducting all over with blast gates which make the dust collection far easier. My particle counter showed to amply clear my shop air I had to let the fan run for a half hour after I stopped making dust.
Although this cyclone made emptying the chips easier, it only moved about half of the air as did that blower when used in dust collection mode. A bigger problem was they recommended far too light weight metal, so every time I turned on my 2 hp commercial dust collector blower, my cyclone flexed so much it kept breaking open its side and cone joints.
I started one of the first woodworking forums and turned that forum over to a friend when I got tired of babysitting adults.
To get more airflow and better collection I bought and installed a new much larger commercial Cincinnati Fan blower with an oversized larger diameter impeller. I later was told this vendor copied the ShopNotes cyclone, then sold copies of this design to all but one of the other small shop vendors who sold cyclones.
Everyone knowledgeable about dust collection ducting design also knows that air at dust collection pressures is like water and will barely compress at all, so any small duct, rough duct, or even sharp angles will severely block our airflow.
No hood will collect many chips while turning but it is a must have for sanding a turning project.
A well designed and powerful dust collection system will greatly improve your woodworking experience. As I kept adding and changing equipment that floor soon looked like a prairie dog village with more patches than floor I so often had to relocate my dust collection. The particle counter also showed whenever I made dust including working with hand tools like chisels and planes that made no visible sawdust, I still made so much fine invisible dust I needed to wear my NIOSH approved 3M dual cartridge respirator mask and use the fan.
Any leak immediately killed the cyclone's ability to separate and filled my filter with sawdust. He said his neighbor and fellow woodworking friend John Dillbeck spotted an idea on an obscure cyclone article.
Donaldson-Torit is the most respected and largest name in commercial dust collection and dust collection filters. When the blast gates were opened on these full down drops they either plugged or launched a huge pile of dust upward. His cyclone moved more air than any other available small shop cyclone, so had the best collection. He simply attached a long hose to that 4" cleanout port and ran it outside, then turned on the cyclone and used an air hose to blow down the filter outsides.
These tests did not even look at working airflow but instead tested with vendor recommended oversized test ducts to generate maximum airflows without attaching ducts, tool hoods, filters, and in many cases even cyclones. After two commercial dust collectors failed to help, my homework led to his having the top commercial dust collection firm install a large cyclone based dust collection system that vented outside.
I then got super busy at work and ended up living in a condo with no place for my woodworking, so all lived in storage. I then found a spreadsheet based on work done at Texas universities that lets us model all seven different classes of cyclones. Those who complained loudly along with many very knowledgeable scientists and engineers who tried to educate us about why we were having problems all got permanently banned from many of the larger Internet woodworking forums.
I disliked the need to always wear my dual cartridge respirator mask and run a strong fan blowing the airborne dust my cyclone missed away outside. Their wood dust collection engineering notes say our filters must be at least one square foot of area for every four cubic feet per minute of airflow and if we want our filters to not quickly get ruined from being over cleaned, we actually need one square foot of filter area for every two cubic feet per minute of airflow. He incorporated a helical baffle better known as an air ramp which did an even better job than Jim Halbert's "neutral vane" so it put a lot less filter plugging dust into its filter.
The fine dust on the filters blew away and vanished outside without the nightmare mess that filled my shop every time I had to clean the cyclone internal filter.
None except my cyclone provides much better separation than the inexpensive trashcan separator lids and one cyclone remains so bad it is only about 85% as good as a trashcan separator lid. This cyclone turned out to be the standard cyclone used to separate cotton from dirt and sand.
Today almost every small shop vendor except for one now builds the revised cyclone design I documented.


With this filter loading, they typically get about three full time months of use out of their fine filters in typical woodworking facilities.
As a result any undersized tool port, overly restrictive tool hood, undersized duct or hose, or dirty filter will add enough resistance to all but kill the airflow we need for good collection. Larry also worked out a clever arrangement where the filter dropped its dust into the collection bag similar to today's cartridge filtered dust collectors. The result is even with the cyclone resistance overhead, his modified blower moved the same air as it did when working without the cyclone overhead. I helped PSI to redesign their their line of blowers and cyclones, plus the cyclone plans they sell with Wood Magazine. Most dust collector and cyclone vendors advertize and sell fine filters that freely pass the fine invisible unhealthiest dust. The PVC is cheap and you can build your own blast gates and hoods from cheap HVAC fittings using my plans. Woodwork was a real pain as all had to be cleared off, then wheeled out, setup, then put back every time I wanted to do anything. I also made a collection hood from a large HVAC register duct that connected to a 6" hose mounted on a heavy microphone stand that could adjust to suck next to my work.
The one vendor who builds a different design came in dead last in a recent cyclone magazine separation test. Jim said he owned one and it was excellent metal work on a junk design that worked worse than his home built upgraded Wood Magazine cyclone.
This let his customers clean their filters by simply turning off their cyclone and blowing down the outside of his filter. I similarly helped Jet Tools and Powermatic with evaluating and improving their new cyclone designs.
Finally, our small shop forums are filled with vendor paid shills and forum administrators who get paid to recommend the same poorly performing cyclones.
Good ducts coupled with a cyclone and good blower and filter are the best investments you can make in your shop. The dust was so bad we had to live in NIOSH certified 3M dual cartridge respirator masks plus run a strong fan blowing the dust away from us outside.
This got ever more difficult as more and more tools and dust collection pieces found their way into my shop. When used for woodworking it is about 99% effective by weight at separating off the heavier sawdust and chips passing only airborne dust and strange shaped pieces that act like sails and get caught in the internal airflows. He just stuck a pipe inside the inlet on his cyclone then moved it in and out until his motor registered maximum amps.
All these changes made a huge difference in my cyclone and its collection, but I remained very unhappy still as collection was still not as good as the dust collector these cyclones replaced and separation remained so poor I still spent way too much time cleaning the fine filters which were quickly getting ruined by sharp chips. They said the blower impeller was a badly cast aluminum mess where the supports were on the wrong side of the blades and that aluminum impellers are no longer recommended for dust collection because when hit by metal aluminum launches sparks just like a sparkler. With this filter at less than one sixth the recommended size it plugged roughly every twenty minutes of sanding or heavy dust production.
That explained why I got almost no collection and lots of clogging with these smaller tools. Larry also made his whole cyclone system from heavy gauge steel that he welded beautifully and coated in hammer tone silver paint. Today every major small shop vendor except JDS now uses variations of my cyclone design shared on my Cyclone Modifications pages.
I rounded the blower housing and painted some of the parts red to accent the looks of the cyclone. When we moved to a commercial space I had the top vendor design and install a good dust collection system.
Airborne wood dust by definition consists of particles sized under 30-microns that vanish with no visible trace when vented outside. That poor airflow provided poor collection and the cyclone separated so poorly it left me to constantly clean the big fine filter cartridge that was an upgrade from the ShopNotes filter box. Although most burn out quickly, if there is dust built up in our ducts this can create a nasty ducting fire. My filter barely lasted a week before it was so broken down that a particle meter it had turned my cyclone into a dust pump that freely passed up to 30-micron airborne dust particles. Likewise, these same forums are filled with first time cyclone buyers that are still convinced that because they spent so much, they got a great product. If you do have static trouble it can be drained off by wrapping a wire around the outside of the ducts and attaching it to the body of the collector and to the machines with screws. I did and within just a few boards my chips that went right through the cyclone had blown a hole in the filter side. Because of my background in woodworking, our dean had me specify and oversee the installation of a cyclone based dust collection system that vented outside for our university wood shop. They found airborne dust on average makes up about 5% of the weight of woodworking created dust and chips. What that inlet pipe extension adjustment does is reduce turbulence by keeping the incoming air from crashing into the air already spinning inside the cyclone. They were most upset about the cardboard dust bin and said it was a fire just waiting to happen.
This cyclone separated so poorly that without a good fine filter it filled my shop with dust. Unfortunately, his cyclone solution was a great "chip collector" but did not move the air needed to be a really good fine dust collector, or handle the airflow required for large shops like mine, so I found myself working on how to incorporate his solutions into my Wood Magazine cyclone. Most large facilities that use woodworking cyclones use a 30-micron filter to capture the strange shaped pieces then blow that remaining 5% of the airborne dust by weight away outside. Jim shared on the Internet and it got mislabeled as a "neutral vane" and it took off with almost all making this change to their homemade and purchased small shop cyclones.
With the horizontal main a little larger it reduces resistance so works better so long as the duct air speed stays high enough to keep the dust moving. Soon after the leading small shop cyclone vendor not only added neutral vanes to their cyclone, they also claimed credit for Jim's work and included it in one of their patents without properly giving credit to Jim.
Using this graduated ducting design program on a one machine at a time dust collection system created immediate problems with keeping the dust moving. When I modeled this modified design, the spreadsheet showed this cyclone reversed the airflow inside too early.
I redesigned and replaced the bad cone and with a cone properly angled with the right dust chute opening so it works. That still left my cyclone working only about three quarters as well as the dust collector the same blower previously powered.
He talked his way onto a couple of national organizations pretending to be an expert, but in reality he knew almost nothing about traditional dust collection, fine dust collection, airflow, blowers, ducting design, or cyclone separation.
This fixed the clogging problem, but the cyclone still only sucked about half as well as my identical powered dust collector. He admitted that his firm falsified their cyclone separation ability, falsified their maximum airflow advertising, and falsified their filters filtering ability.



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