Lessons From a Pro 90° large-radius Blower elbow Small-shop dust collection Create a clean, healthy environment for working with . By Jim Harrold Consultants: Robert Witter and Jeff Hill W hen we first work with Pleated Cyclone wood, taking on a small project filter here and there and buying a power tool or two, addressing the mess of and chips with a broom and dustpan seems reasonable enough…and cheap. But as our passion grows and the projects become more frequent Figure 1: and involved, our investment Anatomy of a small in machines increases as well. shop dust-collection system Canister And so does the sawdust. That’s when we cough up the bucks for one or more portable shop Why central dust- vacuums to help police the area. collection makes sense Eventually, we realize that our pre-separation, and works with paltry militia of maintenance gravity to pull dust downward.” tools falls behind the volume of For the woodworker who fits the He also notes that a whole-shop sawdust and chips. We ask: Is my mold of “dedicated hobbyist,” system has numerous ports shop a candidate for a central one who spends hours every around the room to collect dust collection? Can I even afford week making furniture, having from, not just one port up high. such a system? And, if so, can dust collected at every machine The end result: an overall I plan and install it myself? means convenience and time- healthier shop environment and Working with experts Robert savings. With the right system, reduction of the slippery fine Witter and Jeff Hill of Oneida cleanup at the end of the day dust on the workshop floor. Air Systems, a major player may amount to five minutes The downside? Cost. For a in small-shop dust collection, instead of half an hour or more. one-man 20 × 30' workshop with we’ll help you answer these and In addition, according to Jeff, a standard layout of stationary other questions, and provide “a good central DC will cycle machines and portable power you with several options. By and clean air in a shop more tools, the price tag can run as story’s end, you’ll know what’s effectively than any ceiling (air– high as $2,000 ($800 to $1,300 involved and how to proceed filtration) box. It moves more for a quality collector and without46 woodcraftmagazine.com getting mired in math. June 2009 air, has better filtration and the rest for fittings, pipe, and 6" pipe

7" pipe 7" to 6" wye 45° elbow

hose). This high-end approach would include an efficient two- stage cyclone dust collector 6" to 5" with metal pipes and fittings. reducer However, you can work up to a whole-shop system by starting with a quality dust collector and filter and adding ductwork in stages as your budget allows and needs arise. Says Robert, “Customers tell us that they wished they had installed a cyclone system While this portable 1½ hp dust collector can connect to two machines, with ducting first, instead it works best collecting from one at a time. Consider using blast of spending years with bags, gates to improve efficiency. 5" pipe mobile collectors, overhead units, masks, and other less effective measures.” But for the hard-charging weekend bag collectors pump fine collector (the most horses warrior, there may be a less micron dust back into the air you can hope to run off 110 Optexpensive for a alternative. portable while retaining the larger volts). These mid-sized units dust collector debris. In this case, upgrade the can connect to two machines collector with an after-market at the same time with dual bag or pleated cartridge with 4" ports or one 6" port. That If budget and space rank among ASHRAE tested-and-rated said, you’re best off capping your concerns, you may opt for 1-2 micron or better/ filter. or blast-gating one a portable dust collector like Or, for another1 2 $200-$300, port and collecting the one shown above. At the you can get a 1 hp dust from one machine Blastat a gate low end, you can pick up a 1 hp Secondary Strategies 5" to 4" reducer unit that’s powerful enough to Let these health-smart measures supplement Flexible hose collect from the biggest chip- your primary collection efforts: maker in your shop for around • Wear an inexpensive dust mask or respirator $200. Of course, it collects from when creating fine dust from sanding, turning, one machine at a time so you’ll and similar fine dust operations. need to move it from tool to tool • Ensure that every power tool has a as you work through a dust port for dust/chip collection. sequence. Be aware, however, • If weather permits, ventilate the shop with a thatTip many Alert of the single-stage box-style window fan to remove fine dust. • Use a shop vacuum for suitable portable power While purchasing the flexible tools such as sanders and circular , and outfit hose to attach to your tools, it with an after-market pleated HEPA filter. also include quick-connecting • Capture sawdust and chips with passive (gravity) adapters (Woodcraft #140259, boxes or bags underneath some machines $6.50) to speed hook-up time. such as a contractor table or mitersaw.

Photo: Doug Rowan Illustrations: Chris Glowacki June 2009 woodcraftmagazine.com 47 Lessons From a Pro

6" wye Opt for central dust collection time. For superior collection portable also lets you save in the category: spend a few the cost of running ductwork more bucks and buy a two- throughout your shop. If you desire a full-service dust- stage portable dust collector. When shopping for a , one that pulls Says Robert, “The objective collector, whether a low-dough from every machine (though is to provide enough CFM mobile unit or a fixed model, no more than one or two at a at the machine to capture brush up on a few terms to time), then Figurelet’s examine 1 the nearly all the dust and then know what you’re buying and parts that make up a system. consolidate and filter it down to assess your needs. See the Follow the anatomy to the smallest particles. woodcraft.com“Glossary of Dust-Collection drawing beginning on page 46 A portable can do this if Terms” below, and then go to and ending on page 53 for an it can pre-separate waste to find a wide understanding of parts,Table pipe 2, D-C and capture 99% of the 1-2 variety of dust collectors. Keep Systemreductions, Parts and installation. At micron fine (flour) dust.” A in mind that manufacturers’ the same time, see claims regarding CFM may be for a rundown grossly exaggerated. Therefore, of individual components. to ensure efficiency, refrain Note that while dust-collection from collecting from two pipes and fittings come in tools simultaneously PVC, plastic, and metal, we unless the collector chose metal here (and for the is 2 hp or greater. Woodcraft Workshop, page Finally, if you do buy a 24), because of the diversity portable dust collector, of compatible parts and to implement one or more of avoid the static electricity the “Secondary Strategies” found in PVC ductwork lines. on the previous page to At the heart of the dust- achieve your goals for a collection system in a one-man Glossary of Dust-Collectionclean and Termshealthy shop. shop is the collector itself. D-C—Short for dust CFM (drawing more debris) than stage) collection container before collection/dust collector. smaller diameter pipes. The reaching the motor impeller; CFM—Cubic Feet per Minute or goal is to keep debris moving, this allows only the dust to rate of airflow. See Table 1 for the and not settling in the pipe. pass through the impeller and CFM required to remove sawdust Single-Stage Dust Collector— collect in a second-stage filter and chips from a A less expensive collector that bag or pleated cartridge. machine to a collector. pulls sawdust, chips, and other Two-Stage Cyclone Dust SP—Referred to as Static debris directly through the motor Collector—An advanced type of Pressure, this is the amount of impeller before depositing it mechanical debris separator, that airflow resistance in a ductwork into a collection and filter bag. employs centrifugal air movement caused by pipes, fittings, airflow Two-Stage Dust Collector— to separate coarse and fine reductions, direction changes, A more efficient collector that material so only ultra-fine micron clogged filter bags, etc. Note that allows larger chunks, chips, and dust reaches the filter. It includes larger diameter pipes have greater sawdust to drop into a (first- a more efficient and quieter fan.

48 woodcraftmagazine.com June 2009 Branch It can be either a single- or under the workshop floor. perpendicularly or diagonally double-stage unit and consists lines stem off the across the shop. (Running it of a blower motor (from 1hp main trunk line via wyes and around the shop’s perimeter is to 3 hp), an impeller, and elbows. These typically step the least efficient way to go.) one or more filters (cloth down in pipe size (often to • Make branch lines as short bag or pleated cartridge), 5"-diameters). The branch lines as possible as well. Work for containing fine dust and may again be further reduced to keep tools within a 30' exhausting air. It contains a to 4"-diameter pipe and flexible radius of the dust collector. removable canister or collection hose, depending on the machine • Locate ceiling drops bag for capturing large debris or tool ports they service. In where vertical pipes won’t such as chips and sawdust. some cases you may need to interfere with traffic flow Depending on the amperage fashion special adapters to and machining operations. and horsepower, it may require collect from some tools, such • Allow for return air a special dedicated electrical as a press. Keep in mind, for collectors installed outlet. For reasons of space however, that the more pipe outside the shop. and noise, many woodworkers length, bends, and restrictions • Include clean-out locations locate the dust collector you create, the greater the in the system for removing outside of the shop in a garage MapSP (airflow out resistance).a plan clogs. (In ductwork laid out or attached insulated shed. in a concrete floor, go with Doing this, however, requires Figure 2: you to include an air return To create your whole-shop Shop Diagrams showing to the shop to replace the air dust-collection system, map Diagonal and Perpendicular removed by the collector. out your workshop plan on Pipe Layouts In a typical one-man shop, paper, locating stationary large 6"- or 7"-diameter machines, power-tool stations, trunkelbows and pipe stem from the cabinets, workbenches, and collector and tie into the main so on. To do this quickly and line, which also may be accurately, use the scaled 6" pipe. This ductwork may run “Dream-Shop Planner” on Figureperpendicularly 2 or diagonally page 64. Draw the perimeter across the shop as shown in of your shop on the grid, and , or along the walls. then cut out the templates that It may hang from the ceiling reflect your tools and storage. joist, attach to walls with metal To help you decide where to straps and fasteners, or run locate machines and your dust collector for maximum efficiency, keep these layout considerations in mind: • Place the biggest chip- makers, such as your planer, , and , nearest to your dust collector. • Make the main trunk line (with the largest diameter pipe) as short as possible to deliver more air volume; run it June 2009 woodcraftmagazine.com 49 Lessons From a Pro

capped Y-fitting cleanouts messy math by adhering to collector via a wye or reducer to remove debris.) the following steps regarding 2fitting). Calculate the linear • Avoid T fittings and sharp pipe runs no longer than 30'. pipe length and fittings needed. 90° elbows which increase This simplifies pipe and dust Use 5" pipes and fittings for static pressure (by putting Tablecollector 2 sizing for most home branch lines, reducing them as two T fittings in a system woodworking shops. Rely on needed to accommodate the tool you cut your airflow in half). to assist you with ports they will service. Pipes of By contrast, long-radius fittings, and note that pipes this diameter can carry a range 90° elbows, 45° elbows, and 1come in metal or PVC; fittings of 425 to 650 CFM,Table making 1 wyes are your best choices. in metal, black plastic, or PVC. them well suited for most of the • Include a floor sweep Use 6" pipes and fittings for tools listed in . Calculate to add convenience to the main trunk (this may be the linear pipe lengths and shop-floor cleanup. Tablereduced from1: Airflow 7" at the main requirements fittings (connectors, elbows, • Terminate rigid duct lines with blast gates and reducers (CFM) for shop machines* or adapters for hose hookups. TOOL CFM PORT SIZE • Minimize each flexible hose 12"-14" 400-500 4"-5" length (from 5' to 10'). Now, locate and tape 14"-20" Bandsaw 400-700 5"-6" your cabinet, tool and, dust (6"-wide belt or less) 450 2"-4" collector templates on the Stationary Belt Sander 550 3"-6" planner grid. If placing your (13"-wide belt or more) collector inside, avoid areas that have a gas appliance with Disc Sander (12" dia. or less) 350 4"-5" pilot lights to prevent the risk Drum Sander (13"-24" wide) 500-600 5" of explosion. Regardless of Floor Sweep 350 6" whether your collector is inside Jointer (6"-8" wide) 350-500 4"-5" or out, use remote switches to easily activate the unit Jointer (8"-12" wide) 450-700 5" from anywhere in the shop. Lathe (mini) 450 5" Next, tape down a sheet Lathe 650-800 6" of acetate over your shop layout and draw out your duct Mitersaw/Radial-Arm Saw 400-600 5" system, including the main (table-mounted) 200 2"-4" trunk and branch lines with Shaper (¾ hp-3 hp) 300-550 4" the pipe widths and lengths 10" Table Saw (contractor 450-600 5" notedFigure and the the D-C fittings. parts list based on your plan or cabinet) (10"-13" wide) 500-600 5"

Floor With your generalized plan on Thickness Planer (18"-20" wide) 785 6" sweep acetate, tally up the specific parts you’ll need. To do this, *If your collector is rated for 1,200 CFM, more than likely you can collect from your label the CFM and port sizes table saw and jointer (450 + 350 CFM = 800 CFM) at the same time. for each tool. To determine 50 woodcraftmagazine.compipe and fitting needs, June avoid 2009 Table 2: Parts for a small shop system wyes, reducers, blast gates, COMPONENTS COMMENTS adapters and caps) needed. If *Rigid metal pipe 1"-9" dia.; home shop needs: from suspending the system from (in 2', 4', 6', and 3"-7" dia.; for straight runs in a the ceiling, consider drop 10' lengths) system; more expensive than PVC. lengths as well. In any case, Flexible hose 2"-, 2½"-, 3"-, 4"-, 5"-, 6"- dia.; for avoid choosing duct diameters connecting rigid branch lines to tool that are too small. Try to run ports. Secured with hose clamps. Tablethe largest 1 diameter you can to the tool ports, referring to 90° large-radius 3"-7" dia.; some adjust to . In some cases you elbow fit; large-radius reduces SP 90° sharp-radius when turning corners. can3 increase the tool port elbow size for better collection. Figure the lengths and 45° elbow 3"-7" dia.; for gentle turns. diameters of the flexible 4hose and hose clamps needed to match the tool ports. 45° Wye-Fitting 3"-7" dia.; preferred fitting for branch Include 2"-wide aluminum lines; offers less SP than T-fittings. Branch arms can serve as reducers. tape, industrial grade silicone sealant, sheet metal screws, and metal Floor sweep Attaches to floor and system; adds 5 (2 × 8" opening) convenience to workshop cleanup. strapping for hanging pipes. Make a D-C parts list on paper for purchasing Choosingand installing. a whole-shop Connectors 2"-7" dia.; Connects pipe (crimped, sections together w/screws dust collector uncrimped) and tape; same dia. as pipe.

Blast gate 3"-6" dia.; install w/screws/ If your one-man home shop silicone at end of branch line; Table 1 requires adapter for hose. contains a variety of machines like those listed in / 3"-6" dia.; connects flexible and the ductwork (trunk and hose adapter hose to system from tool. branch lines) does not extend Reducer 6" to 5", 5" to 4", 4" to 3", 3" to 2" beyond 30' from the collector, dia.; allows for stepping down to pipe, fitting, hose, or tool port. your options are simple. For single-tool collection (only Tool port 3", 4", 5", 6", 7" dia.; mounted / with flange to tools for connection and for one blast gate open1 2at a stepping up to larger port. time), consider a 1 - to 2-hp End cap 3", 4", 5", 6" dia.; used to collector. For collection from seal and terminate the two tools at a time (with all end of a branch line. but two blast gates closed), opt for a 2- to 3-hp collector. *Schedule #40 (white) PVC pipe comes in 3"-, 4"-, and Use any more than that and 6"-diameters; thinner schedule #20 (white) PVC pipe comes in 3"- and 4"-diameters only. Both come in 10' lengths and accept a full you’re indulging in overkill. range of plumbing fittings found at home centers and black plastic D-C fittings like those If your shop is more than a sold at Woodcraft. Costs: 4"-dia. × 10' PVC pipe, $7.65; 4"-dia. × 6' metal pipe, $13.29. one-man shop and commercial in nature, seek expert help. June 2009 woodcraftmagazine.com 51 Lessons From a Pro

Install a metal D-C system step by step

With your system parts on hand, gather the tools and materials you’ll need for installation. For the metal system featured here, we used a tape measure, felt tip A B pen, reciprocating saw equipped/ " Jeff used a pair of hose clamps and a short piece of flex hose 1 with a metal cutting blade, a 2 to connect the collector to the dust bin; he installed the cordless drill, screw driver, cartridge filter with star knobs, bolts, and washers. sheet-metal screws, tin snips, a crimping tool, silicone caulk, a caulk gun, aluminum tape, and hose clamps. Now, solicit a their installation, following your 1helper and follow this sequence plan. Then, beginning at the for a quality installation. dust collector, fit connectors,Photo C Assemble the dust-collector elbows, wyes, and pipes at its planned location, following 3together as shown in instructions accompanying the to build the main trunk line. unit. (We attached the motor Seal all joints withPhoto aluminum D C to the cyclone barrel, and then tape as you screw components After joining male and female bolted on the cyclone cone. together as shown in . parts, Jeff secured them using Rather than secure the unit A second method of sealing three or four #8 × ½" sheet-metal to the wall with a bracket, we pipePhoto is to Euse an industrial screws around each joint. assembled an optional iron grade silicone sealant as shown frame for sturdy, level support, 4in . Both measures Tip Alert and then addedPhotos the dust-binA B lead to an air-tight system. 2and cartridge filter assemblies Build branch lines that lead If possible, do as much of the as shown in and .) to each tool, terminating them assembly on the floor for ease of Lay out the pipes and fittings with wyes and reducers, blast construction. on the floor in the vicinity of gates, and hose connectors.Photo F Expert D-C layout When needed, cut pipe lengths services to fit as shown in , If you intend to install a D-C system, note that Oneida offers a professional planning service to help you lay out and size your system, develop a parts list, and obtain installation help. This is free of charge with purchase of a 3 hp or higher system. D E Contact Oneida at (800) 732- Fortify and seal each joint with adhesive-backed aluminum tape, 4065; online: oneida-air.com. cutting strips long enough to circle the joint at least twice; lay down a of silicone along joint lines as an alternative sealing method.

52 woodcraftmagazine.com June 2009 F G H Cut pipe with a reciprocating Cut strips of metal strap, bow it Crimp the edges of a fitting (in saw and metal-cutting blade; a around the pipe, bend up end this case, a reducer) for a snug helper rotates the pipe during taps, and screw the strap and fit in the mating component the process to maintain a pipe in place. Solicit a helper using a metal crimping tool. controlled, on-the-mark cut. to hold the pipe in place. Secure the piece with screws. Tip Alert measuring and marking them Photoneed to H crimp a pipe or fitting Improve collection efficiency on with a pen. Allow for overlapping for an inserted fit as shown in tools by replacing the factory 5of pipes and connectors at joints . With the installation port with a larger shop-made (usually about 1" at each end). complete, close the blast gates, one. (For instance, we changed Hang the assemblies from activate the system, and nlisten out the 4" factory port on our the ceiling joists or along for air leaks at each joint. Plug jointer with a 5" port made from the wall with metalPhoto straps G any holes with silicone.4" hose 1/2" with a 5" opening 6snipped to size and screwed in and a 5" flanged metal port.) place as shown in . Connect needed lengths of sized flexible hose (less is best) from branch line ports to machine ports, using hose Adaptor 5" to 4" wye clamps. In some cases, you may Installing a PVC system and/or aluminum tape to prevent air leaks. End cap • Some metal components, purchased at a A Note of Caution: While we include a discussion home center, may be needed to connect of a PVC ductwork system in this article, we do a PVC system to the dust collector. not recommend it. And while you can find PVC • Do not glue up all of the joints. You may have ductwork systems in small shops across the to pull sections apart to deal with clogs. country, know that NFPA / OSHA opposes using it • T and other tight-radius fittings and small diameter in this application due to the potential for causing pipes will significantly reduce efficiency. electro-static shock and fire. But if you choose • Ground the PVC system by running braided metal this route, consider these installation pointers: wire inside the PVC piping, fittings, and flexible • When assembling the components of a PVC hoses from machines to dust collector to reduce system, note that black plastic fittings, like the static electricity buildup. Connect braided wires blast gates and reducers sold at Woodcraft, and together at joints with wire nuts. (Consider the cream fittings all complement the system. Woodcraft’s Anti-Static Kit, #812502, $17.99.) Still, make sure you have the needed adapters Reduce the shock potential by spiral-wrapping so parts connect snugly. Seal joints with silicone the system with a grounded braided wire.

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