Cyclone Dust Collector Design,Fine Woodworking Newsletter,Power Wood Carving Tools Review,Woodworking Tools List Pdf - New On 2016

04.07.2015, admin  
Category: Dresser Woodworking Plans

We have over seventy years of chip collection science and at least thirty years of professional fine dust collection science define the minimums we need for good dust collection.
Since the 1920s fire marshal and building codes required good chip collection in most industrial facilities, so chip collection remains well understood.
At least thirty more years experience by those firms who guarantee customer air quality also establish well tested fine dust collection minimums.
At first this requirement to move nearly three times as much air makes no sense because we all know that the slightest breeze will blow dust highlighted in a beam of sunlight.
We need to understand wood dust causes a variety of immediate health problems and some long term adverse health effects. All fine dusts pose so much health risks that the EPA sets standards of no more than 1.5 micrograms per cubic meter. Sadly, most even clean looking shops fail their air quality tests due to a buildup of residual dust. The medical experts strongly recommend that vent the fine dust outside and if we have to filter that we use filters that separate down to at least 0.5-microns.
The problem with such fine filters is that when we provide the minimum of one square foot of filter area for every 4 CFM of airflow, woodworking makes so much fine dust that our filters will clog after about twenty minutes of woodworking. Sadly, most small shop vendors choose to use this same very open outdoor filter material on their dust collectors and cyclones they sell for indoor use. Small shop vendors foolishly convinced most that cyclone performance is measured in CFM when the reality is cyclones get rated according to how well they separate and blowers get rated based on how much air they move. As discussed on the Cyclone Plan page the cyclone proportions and sizing depends upon the weight and density of the material to be separated, the needed airspeed, the needed collection air volume, and the size of the blower used to power our cyclone. You should pick a material for your cyclone that is easy to work and that you can protect from constant sand blasting. Most find galvanized sheet metal provides the easiest fastest way to build my cyclone design.
Building your own galvanized metal cyclone from scratch takes about twenty hours of metal layout, cutting, and forming followed by about ten five of propane torch soldering.
Plan - You must start with a well tested plan with accurate dimensions such as provided by my cyclone spreadsheet, or use a precut metal kit. Poster Board Full Sized Model - If you lack sheet metal experience make a full sized cyclone from poster board, cardboard and masking tape. Template Rings - Just like the round cardboard rings that held the model round, this sheet metal cyclone depends on use of carefully made wooden template rings to ensure all comes out the right size, that all the round parts stay round, and that all will fit together. Forming - After years of building these kits I learned that good initial metal forming remains the secret to cyclones that go together easily. Joining the top cylinder to the cone and cone to the dust chute requires wooden rings, bent over tabs, or find a sheet metal shop that can roll a lip. I prefer soldering because it quickly makes the best looking and strongest cyclone and requires only an inexpensive propane torch. The easiest homemade way to build this cyclone is to use screws or pop-rivets then use polyurethane duct sealant.
One of the nicest ways to build the cyclone is to use a spot welder like we use to build our cyclones then solder all the joints. A few friends have built my cyclone design from 16 to 18 gauge metal then used a TIG welder to make very strong welded joints. Finally and perhaps the most elegant way to build a cyclone with the nicest joints uses 16 to 18 gauge metal, a professional heavy sheet metal fabrication plant, and all laser welded seams and joints.
My cutting started with the little rectangular dust chute to get a feel for working with my tin snips. Many industrial processes require dust-size pieces of process material to be collected for reuse or disposal. In industrial applications, cyclone dust collectors are typically fabricated out of steel and are generally large.
One way to decrease the size and cost of cyclonic dust collectors is to add a ground plate to the design. Because the secondary air stream pushes particulate toward the collection end of the chamber, this design of dust collector does not rely on gravity for collection and may be installed horizontally instead of vertically. The unique design of Aerodyne’s SplitStream Dust Collector yields a higher efficiency than traditional cyclone dust collectors. Due to excessive shipping damage and the need to remake too many cyclones my son stopped selling built and partially built kits to anyone who cannot make a local pick up. Most small shop activities including woodworking make dangerously high amounts of fine invisible dust. When many asked for help with the sheet metal work I designed a kit cyclone for my son to sell in 2002 as a way for him to earn a little extra spending money. The first two who tried to make these kits failed, then in 2004 Ed Morgano, a retired plastics engineer, created Clear Vue Cyclones to help hobbyists and small shop woodworkers with affordable cyclones. Ed Morgano notified me well in advance that he had to sell his Clear Vue Cyclone business and retire on May 1, 2010.
His cyclone kits with cut metal parts save about twenty hours work to chase down metal, do accurate layout, and provide laser cut metal parts accurate to 0.002".
The 18" diameter P1800 sheet metal cyclone kit my son offers lets you build the most current version "Bill Pentz" cyclone design sold by Clear Vue Cyclones that you can also make from my free plans on these web pages. These precision laser cut 22-gauge galvanized cold-rolled sheet steel parts let you build a tough rigid cyclone that needs no reinforcement. This is a kit that just builds the cyclone body, so you need to make or purchase all other items.
You can make this kit into either a left-handed or right-handed cyclone, but most motors require impellers that turn counterclockwise when viewed from the blade side which requires left handed cyclones for best air movement.
The detailed plans shared on my cyclone and blower designs remain just a little larger than our kits. My son sells the bare unformed flat metal cyclone sheet metal kit for $199 plus $112 continental U.S. Also NFPA no longer recommends use of aluminum alloy impellers in dust collection systems because when hit with steel these impellers shoot off sparks like a sparkler which can trigger a fire. Clear Vue Cyclones, Electric Motor Warehouse and Electric Motor Repair and Sales of Greensboro, Inc.
A 14" BC diameter impeller is the smallest to power my cyclone and have the 1000 CFM airflow recommended by those firms that guarantee customer air quality. Because I selected a 5 hp motor as ideal to power these cyclones and the optimum 14" diameter BC impeller only pulls about 3.5 hp maximum, I came up with larger impellers to use that extra horsepower and let us use smaller ducts. When Clear Vue Cyclones closed temporarily I contracted with a local machine shop to make an even further improved impeller design that is a taller 15.5" diameter impeller. Also you need some scrap wood to make some jigs, fixtures, and some wooden rings to help hold all together while you build your cyclone. Cyclone and blower kits get cut weekly, so typically get cut and shipped within two weeeks.
These cyclone kits contain large metal parts that require large oversize boxes making for expensive shipping. Although all of these designs are mine I own no part of this kit business and am a reluctant retiree who got volunteered to help while my son gets finished up with school and gets this business going. Over 10,000 small shop owners use cyclones of my design and at least 6000 built their cyclones from these plans and building instructions.
Chip collection means picking up the sawdust and chips that we would otherwise sweep up with a broom.
Translated, less than two tiny thimblefuls of the fine invisible dust will cause a large two car garage sized shop to fail an EPA air quality test. Residual dust consists of that dust either missed during collection or with particle sizes so fine it passes right through our dust collector and cyclone filters. Many of these vendors carefully pick their filtering material so it just gets rid of the visible dust and freely passes the unhealthiest invisible dust right through.
Hundreds of credible independent tests done by scientists, engineers and medical researchers show my 18" diameter cyclone with a 1.64 cone ratio provides the best possible small woodworking shop fine dust separation in a cyclone that just fits under an 8 foot tall ceiling. Many make their cyclones out of typical 30-gauge thin galvanized sheet metal used to make HVAC duct. Even if you have a precut metal kit, first trace all the parts onto poster board and build a full sized cyclone model.
Those who do not use template rings during inlet, cone, and air ramp installation and soldering invariably end up with junk having to start over because they either cannot install the cyclone top or mate the cone. If you do not remove that coating your solder and polyurethane sealant will not stick and building your cyclone will create a mess.
They use powered rollers, brakes, and seam forming machines that let them make one of these cyclones quickly.
Although screws and pop rivets work well, are easy, and do not require a lot of practice or special tools, they much such an ugly looking cyclone I don't recommend either. If you mess up at all here or are sloppy in your cutting, the cyclone will not go together well at all.
I did the same with the dust chute ring verifying it was the same size as the bottom of the cone. A ground plate is a stationary plate located at the end of the chamber (opposite the air inlet) that causes the cyclonic action to take place in a shorter space.
This may save significant cost by avoiding the need to cut a hole in the roof to accommodate a vertical dust collector, and it may save maintenance costs by avoiding condensation issues common with outdoor temperatures. Now with increasing air standards, expensive fabric filters and added limitations of moisture and heat, the best solution is to use cyclone dust collectors before final-stage filtration.
Woodworking makes about 1.6 pounds of fine invisible airborne dust with every one hundred pounds of sawdust.
You can get good fine dust protection as you work by wearing a properly fit NIOSH approved dual cartridge respirator mask such as the 3M 7500 series. For collection we need tools modified with hoods that control and capture the fine dust, ample airflow to collect the fine dust, and then to either vent the fine dust outside or use ample filters. Today's reasonably priced air quality monitors show that even when not actively making fine dust those who vent their dust collection inside get dangerously high fine dust exposures in clean looking shops even when we are not making fine dust. They all still sell typical dust collectors and cyclones with about one third the airflow we know it takes for good fine dust collection.
The traditional commercial wood dust solution uses gravity based cyclone separators that separate the airborne dust from the heavier particles then vent that airborne dust outside where it quickly dissipates.
Unfortunately almost all cyclone vendors sell variations on the same 1963 public domain gravity based cyclone design that are engineered to vent the airborne dust outside. I came up with a totally new kind of cyclone design optimized to also separate off the airborne dust and shared plans to build this improved cyclone on these web pages in 2000.


He provided excellent service and priced his clear cyclone for little more than the cost to build a kit.
You can make this as either a left or right handed cyclone simply by which way you roll the top. This kit only contains the flat sheet metal parts to build the cyclone body and an inlet transition to connect the cyclone to a 6" flex hose or duct. You need a wooden cyclone top, blower housing, blower impeller, blower motor, electrical parts, mounting hardware, hoses, ducting, fittings, and dust bin.
Unfortunately blowers smaller than 3.5 hp and impellers smaller than 14" in diameter fail to move ample air to provide good fine dust collection.
Using the solder and flux recommended on the Build Cyclone pages makes for smoother joints and a better looking stronger cyclone that provides higher separation efficiency. I recommend you power our cyclone with a backward curved (BC) material handling impeller to minimize blower noise. I paid to have this impeller tested and certified and made arrangements for two firms to make and sell my impeller design. This includes wood to make 6" and 9" rings to ensure the cyclone inlet transition, the blower outlet transition, and the cyclone outlet chute are each sized correctly and made round. Never mount your cyclone directly to a wall or ceiling because that will transmit the sound throughout your shop and home if attached. I ordered up enough cut cyclone and blower pieces to cover at least six weeks of expected sales. I provide my help at no charge and my son works at near minimum wage so we can help you out with affordable cyclone and blower kits. You can build one of these cyclones if you patiently take your time and follow the instructions. Good chip collection requires enough air speed to pick up the dust and chip, enough air speed to keep that material moving through our ducts, and enough air volume to accommodate the volumes of dust and chips each different size and type of machine produces. Likewise we need that same 2800 FPM to keep our horizontal ducts from building up dust piles. The medical experts know fine dust poses so much health risk that they recommend an even tougher standard of only 1.0 micrograms per cubic meter of air. So much dust gets passed through that most small shops build up such high amounts of fine invisible dust that just walking through the shop without doing any woodworking launches enough airborne dust to fail an EPA or medical air quality test. This sized cyclone works with blowers as small as 1.5 hp, but that sized blower will not power a cyclone, filters, ducting, and tool hoods and move the 1000 CFM we need at our stationary tools for good fine dust collection. A commercial ducting shop with powered sheet metal tools can typically cut and build one of these cyclones from the cut metal in a few hours which is why many have these cyclones built for them at metal shops.
Drilling them out after is a real pain because the metal that flares the rivets spins unless you use something like Vise-Grip pliers, plus that metal shaft is so much tougher than the rivet body, you often end up drilling through the side of the rivet into the cyclone metal. If you leave the oil on the parts you can not make your solder stick, the caulking will not stick, the glue will not hold for the interior rubber blast plate, and paint will not stick to your cyclone. Also, by drawing secondary air from an appropriate source, drying, heating, cooling or may be combined with the dust collection process, further reducing costs. Most find that by the time they purchase a metal cyclone kit, the motor, an impeller, and do the work to build their own cyclone they have spent more than it costs to buy a complete cyclone from Clear Vue Cyclones, so most buy from Clear Vue.
Most dust contains chemicals that cause immediate problems such as irritation, allergies, toxic reactions, and increased cancer risk. This is enough fine dust to cause over 15,000 typical two-car garage sized shops to fail an EPA air quality test that would shut down a commercial office building. Because woodworking makes so much fine dust and this dust lasts nearly forever unless it gets wet, we also must protect ourselves from a buildup of fine invisible dust. Our small shop vendors are to blame because they ignore industry standards and choose not to engineer their tools or dust collection equipment.
These typical gravity based cyclones pass 100% of the fine filter ruining dust into the filters. We reached an agreement where only Clear Vue and my son can make and sell my cyclone design in trade for a royalty.
I very much wanted another reliable firm to take over the manufacture of my cyclone design.
Some like me enjoy making our own things or really want a metal cyclone but are layout and cutting challenged.
He does not sell blower housings, wooden parts, wooden transitions, motors, impellers, blowers, relays, cords, plugs, different sized cyclones, custom sizes, etc.
These kit parts produce a more refined cyclone than my basic design because the kit includes tapered fittings to better attach hoses, plus etched alignment lines, alignment notches, tabs and slots that speed up assembly and accuracy.
These airflow requirements were set by those firms who guarantee customer air quality after decades of air engineering and experience with how much air we need to move at our larger stationary tools for good fine dust collection.
The first firm changed hands and the new owners chose to discontinue impeller sales leaving only Clear Vue making my design. When Clear Vue reopened, they found the cost to make my revised design too expensive so they resumed making the prior 15" and 16" diameter impellers.
You can also make a simple wall mount wooden frame that will support your cyclone and blower well. Most need one small can of auto body filler, a large tube of spot or glazing putty, two cans of paint primer, and three cans of spray paint for the cyclone and collection bin. Even my heavy commercial cyclone that came carefully packed in a molded 2" Styrofoam protector arrived so damaged it required replacement.
Please start by reading over the Introduction then the Dust Collection Basics followed by the Medical Risks and Doctor's Orders pages.
Please read the Cyclone Plan page before starting on building your own cyclone so you understand more about this system. Decades of applied science and practical experience helped the major dust collection firms build tables that show exactly how much airspeed and air volume we need to collect the different materials. The major difference between good fine dust collection and chip collection is we need to move far more air, roughly 1000 CFM to get good fine dust collection at our typical small shop stationary tools. Just slapping our denim shop apron launches enough of this fine dust to fail either an EPA or medical air quality test.
In fact, when a few of the sealed pyramids were opened researchers found considerable wood dust that still lingered settled on every surface. Pre-filters work, but they again require lots of cleaning so most commercial facilities instead use much more open filters that they vent directly outside where the airborne dust blows away.
Blasting the inside of a cyclone with this damp hot sand causes many commercial cyclones to rust and wear through right at the point where the incoming air hits the outer cylinder wall. Then carefully work out your technique to form the rounded cyclone parts and fold the rectangular inlet without any wrinkles and unnecessary bends.
Some woodworking clubs held cyclone building sessions where they went together to buy or rent a spot welder. The one local firm with this equipment charges $80 an hour which comes to about $400 to weld up one of these cyclones.
Some dust collector manufacturers line their cyclones with abrasion resistant tiles to prevent wear. Although I am still neither an owner nor employee and only license my designs to Clear Vue, I continue to work with them to provide whatever help I can. Also, these fine airborne dust particles have very sharp barbed edges that irritate and damage our respiratory tissues.
Many different hand and power tool operations launch fine invisible dust in spite of our best collection efforts.
Most small shops have so much fine dust built up that just walking around stirs enough residual fine dust back airborne that we fail air quality tests. Most tools need hood upgrades simply because our blades bits and cutters throw off dust filled air streams that move in excess of one hundred miles an hour, yet our dust collection systems only move air at around forty five miles an hour.
Almost all simply make smaller copies of outdoor industrial dust collectors and cyclones then supply them with the same outdoor filters designed to pass the fine invisible dust that dissipates outdoors. Commercial firms who offer filtering options for their cyclones must use graduated banks of fine filters or huge fine filters. Independent medical school testing shows my cyclone design separates almost all of the fine airborne dust by weight and 99.9% of all particles five times smaller than its nearest competitor.
To make a little extra spending money he will continue to build about one cyclone a week during the summer college vacation and about one a month when school restarts so maintains a waiting list. Just like the current Clear Vue Cyclones the metal kit parts improve on my web page design with tapered fittings, transitions, and other features such as alignment marks, notches, and cutouts to ensure proper fit and nice tight joints. My web pages share detailed building instructions, jigs to make assembly easier and links to Clear Vue and other vendors that supply all parts needed to build your own cyclone. Use of the 30-gauge air ducting metal that other kit plans recommend creates a cyclone that requires additional reinforcement.
I recommend use of a short piece of the right sized flex hose to go between the cyclone transition and your ducting mains to help keep the noise down as the flex does not carry the vibrations from the cyclone. Although this kit is slightly shorter than the cyclone on my Cyclone Plans pages it only fits under a standard 8' ceiling if you use a short collection drum. If you want the blower side metal you must either buy it with the cyclone kit or get it cut yourself. The blower bottom wooden plate is secured with six screws that let you position the blower to face in any direction you desire.
You need at least a 14" diameter BC impeller powered by at least a 3.5 hp motor to move ample air to drive this cyclone, push air through my recommended filters and still supply the 1000 CFM airflow needed to provide ample airflow to meet the major air quality standards.
I should soon have detailed plans up on my Build Cyclone page that shares how to build this wall mounting frame. More than 10,000 people now use my cyclone and most built their cyclones without kits just using the instructions from my web pages. And this causes a big problem because adding fine enough filters to existing dust collectors and cyclones simply clogs and quickly ruins the filters. Cyclones that don't use my more efficient design need at least 4 hp motors to move the same amount of air. This is clearly the way to go if you are building a very heavy larger commercial unit, but not affordable or practical for most small shop cyclones. The peer reviewed medical research clearly shows every exposure to fine airborne dust particles that are invisible without magnification causes a measurable loss in respiratory capacity.
Without good hoods to control and capture these fast moving air streams our dust collection systems lose this race every time.
When used indoors these units create such a big fire danger that fire marshals immediately fail shops with uncertified indoor dust collectors or cyclones. Our small shop vendors decided that these fine filters the experts recommend cost too much plus their crude dust collectors and cyclones constantly clog these fine filters making for a cleaning nightmare and frequent expensive filter replacement.


Woodworking makes so much airborne dust that commercial shops with fine filters need automated cleaning systems or the filters will load up roughly every twenty minutes of heavy production that the dust collection system barely passes air. That second place cyclone just happens to be my improved version of the traditional gravity based cyclone that most small shop vendors still market. His good work and word of mouth advertising from many happy customers turned his part time Clear Vue venture into one of if not the top supplier of small shop cyclones. You will need to add your own motor, impeller, blower housing, electrical, wall mount, dust bin, and ducting.
Our blowers create enough suction to cause lightweight metal to snap and pop when the cyclone gets turned on and off. You need a taller than 8' ceiling to use a 55-gallon drum or standard 30-gallon galvanized trashcan for your dust bin.
This also lets you remove the blower housing and cyclone without having to take down the heavy motor and impeller.
You need to make sure that the motor when viewed from the motor shaft end turns counterclockwise and that you also get an impeller that is designed to turn counterclockwise, or that you can reverse the motor direction. In either case you will need to provide the screws, bolts and miscellaneous hardware to mount your cyclone. He received more orders for partially and fully built cyclones than the two of us can build working full time for six weeks.
If you are not willing to take the time to read over and follow my web page building instructions or you expect help making an undersized dust collector power one of these cyclones amply to get good fine dust collection, then these kits are not appropriate for you. To provide a little safety factor most woodworking dust collection engineers design their systems with at least a 4000 FPM airspeed. Because airspeed falls at roughly twelve times the distance squared, we lose the airspeed we need to pull in the fine dust before normal room air currents blow it away unless we move lots of air or totally contain all the dust as it is being made. As a result, most small shops that vent their dust collectors and cyclones inside build huge amounts of residual dust then just about any activity in our shops launches this dust over and over. Existing gravity based cyclones separates off almost all of the visible dust by weight which keeps our filters from quickly clogging with larger chips, but still results in fine filters plugging roughly every few hours of use. One of these rings goes into the cyclone top and the other just above the cone to hold all round.
One of the two 18" rings becomes the cyclone top which holds the internal cyclone outlet cylinder and lets you mount the cyclone to the blower. Careful MIG welding does an equally fine job and is used on at least one commercial hobbyist cyclone. You can buy special solder at welding supply stores designed that work with almost all galvanized metal. Ignoring the often toxic chemicals found in wood dust, these particles are so sharp and pointed they easily damage our respiratory systems.
In addition, most traditional tool designs have such poor dust collection built in that they spread dust from all around their working areas. Worse, our small shop vendors then play games pretending that these units provide good health protection when they are actually nothing more than fine dust pumps. This heavy dust load and frequent cleaning so rapidly wears out our fine filters that most commercial firms must replace their expensive fine filters quarterly. This new type of cyclone works exceptionally well and hundreds have shared saying things like, "I had to clean out my prior cyclone filter two or three times a day, but with your design I now only clean every three or four months." And, "Bill, this cyclone is amazing.
Between Clear Vue, my web page plans and kit sales now worldwide more than 10,000 small shop owners use and consider my cyclone design the best available. Cone size uses the near ideal 1.64 sizing multiplier to make them more efficient at separating off the finest unhealthiest dust. All other small shop cyclone designs require you to take all down including the heavy motor and impeller every time you clean your impeller or have to remove a jam from your cyclone.
Many find that if they have the inside of the cyclone and blower sprayed with pickup truck bed liner or rubberized automotive undercoating (not tar or asphalt based), that they have much quieter systems. You still end up having to grind off the screws inside the cyclone to keep strings and shavings from hanging up on the screw threads that stick inside the cyclone, so I prefer using pop-rivets.
The health insurance data clearly show that fine dust exposure causes most woodworkers to develop serious respiratory problems that often adversely impact our quality of life and worsen age related health problems.
The EPA sets such tough limits that hand sawing just over seven inches of three quarter inch stock produces enough fine dust to cause a typical two-car garage sized shop to fail its air quality tests. Our particle meters show it takes about a half hour to thoroughly clear the air in most shops after making fine dust. To capture this fine dust before normal room air currents blow it around it we must build a big bubble of air around out tools that moves fast enough to pull in the fine dust as it is made. Only about one in seven develops allergic reactions and only about seven out of a thousand develop such bad immediate problems that until we got the Internet this fine dust problem got ignored. The reality is with fine enough filters these traditional dust collectors and cyclones get so plugged they no longer even do a good job picking up sawdust and chips, let alone provide good fine dust collection. Except for Clear Vue Cyclone and these kits all other small shop cyclones use variations of these same gravity based cyclones which provide often even worse separation than the commercial units.
All cyclone blower impellers should be regularly inspected and cleaned to remove any built up pitch otherwise the impeller can get out of balance and damage your motor bearings. Finally, most small shop stationary tools require at least 350 cubic feet per minute (CFM) airflow to pull in the volumes of dust and chips they produce.
Most filters are open enough that the fine dust accumulates in the filters, so when we first turn on our dust collectors or cyclones the initial blast of air blows lots of this fine dust right through our filters.
At least 6,000 people worldwide now use my cyclone and get great fine dust collection using 14" impellers on 5 hp motors. After your full sized cyclone fits well those who cut their cyclones get to use these templates to make your cyclone metal and wooden parts.
A 6" disc gets used to keep the cyclone dust chute, the cyclone inlet transition, and the blower outlet transitions round. Most small shop vendors make their cyclones using either spot welding, MIG welding, or TIG welding. Fine invisible dust particles cause so much harm that the EPA indoor air quality standard fails a large two-car garage sized shop if just two tiny thimblefuls of fine dust become airborne. Medical experts recommend always amply protecting yourself from this dust, but most of the protections we buy work poorly. Cyclones move lots of air and can suck up trim pieces, scraps, small tools or other items like my shop apron.
A 6" clamp screwed to a 3" clamp creates the 9" clamp you need for the cyclone air outlet cylinder.
Careful testing shows that reducing that airflow to 900 CFM ends up with five times more airborne dust. I invented my cyclone design to also separate off 90% of all the fine airborne dust that other cyclones send right into the filters.
Their entire effort took less than an hour and left a pristine near perfect looking cyclone. These tables show it takes about three times more air to pull in the fine dust as it does to collect the sawdust and chips. These filters trap the visible dust leaving clean looking shops while they also freely pass the unhealthiest invisible dust right through.
Reducing to 800 CFM lets fifty times more airborne dust escape collection and airflow below 800 CFM results in such poor fine dust collection that shops subject to inspection would immediately be shut down due to dangerously high airborne dust levels. As a result the peer reviewed medical studies show every fine dust exposure causes a measurable loss in respiratory capacity and some of this loss becomes permanent.
As a result people have been using my cyclone without harming their fine filters for more than ten years versus needing to replace them quarterly with other designs. In other words small shop vendors sell DANGEROUS DUST PUMPS instead of their advertised fine dust collection. Unfortunately our small shop vendors sell far more open filters that trap the visible dust and freely pass the fine invisible unhealthiest dust. After two months operation his kit business proved profitable and ran smoothly, but was something he lacks the time or desire to do as more than a way to make a little extra spending money.
My certified air quality inspection showed my clean shop immediately failed as soon as we turned on my cyclone before we did any woodworking.
This doubles the time between cleaning filters but so rapidly builds the levels of the fine unhealthiest invisible dust that in most small shops just walking around stirs up enough fine dust to fail EPA air quality tests without doing any woodworking. Making your own cyclone also requires you to precisely cut an 18" diameter disc, a pair of 9" diameter discs, and a 6" diameter disc used to size and ensure the cyclone round parts stay round during construction by clamping the metal tightly to these discs with the worm drive clamps.
He uses a bearing bit to follow these templates so his parts look better than the multiple pass CNC cuts, but make a monster dust cloud and take too much time to make. They also had a special seamer that made the cyclone center joint between the cone and cyclone top, sealed the inlet to the outer cylinder, plus it put the rings on the bottom of the cyclone and both transitions. These discs are required to be kept in place during construction to also ensure adding the cyclone inlet does not cause the upper cylinder to warp and lose its ability to fit to the top ring. We had a few other challenges like running our laser cutter out of sheet metal and our old blower transition not fitting my newer blower design so we also had to hand make transitions.
This is particularly bad news for small shop and hobbyist woodworkers because the insurance data is for larger facilities that almost always vent their fine dust outside. Woodworking creates so much dust filter makers recommend using a cyclone to remove the larger particles plus at least one square foot of this expensive filter area for every two cubic feet of air moved.
Typical small shops that instead vent their dust collection inside average about 10,000 times higher airborne particle levels.
Using screws and pop rivets makes for an uglier cyclone exterior, but where it counts is on the inside. Unfortunately, most cyclones freely pass the same sharp barbed particles that damage our respiratory systems. Although private industry spent fortunes to prove that wood dust poses no major health risks, the reality shown by peer reviewed medical studies is that any woodworker who does not protect themselves will experience trouble, often in their later years of life.
Woodworking makes so much dust that filters fine enough to protect our health need constant cleaning and cleaning also rapidly wears out fine filters.
Between the need for constant cleaning and high cost for filter replacement most commercial firms choose to use cyclone separators and vent outside.



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