Build your own Super Cyclonic Dust Collector

Transcription

1 Multi Cyclone DIY Dust Deputy Kit ZBI To collect dust safely and efficiently Build your own Super Cyclonic Dust Collector The Multi-Cyclone DIY Dust Deputy TM Collector gives you twice the suction of a single vacuum for bench top tools. AXD Revised

2 B1 With the D.I.Y. Dust Deputy, you only receive the plastic cyclone. You must supply all hardware and buckets yourself. 2 1/2 to 3 Hose Adapters Air Box - Top Part B1 Materials & Hardware Included: (3) D.I.Y Dust Deputys TM - AXD (3) Gaskets for Cyclone Base - AXG (2) 3 to 2.5 Reducers - DRL (1) 4 to 2.5 Reducer - DRL (1) 2.5 x 5.5 Hose - AXD (7 ) 3/4 Neoprene Gasket - RGZ (1) 1.25 Fl. Oz. Caulk Single - ASC (1) Instruction Manual - ZBI Required: A1 A2 B2 A3 Air Box - Middle Part A1,A2, & A3 Air Box - Bottom Part B2 (1) 3/4 Plywood or Medium Density Particle Board. Interior 3/4 Plywood is best for the dust bin lid, however exterior grade & medium density particle board also work well. (1) Dust Container - Must be large enough for 3 Dust Deputy cyclones and strong enough for the suction of the vacuum or fan/blower. Example: Standard 35 or 55 gallon fiber or metal drums. C 3 Dust Deputys 4 I.D PVC Pipe Dust Deputy Connector Part C 4 I.D PVC 90 degree Elbow E (2) Wet/Dry Shop Vacuums. Any shop vacuum can be used. We used Shop Vac s Bucket Max 600BH150 for approx. $20.00 each and are available at local big box stores. These can be used on a 110v 15 / 20 amp circuit. For excellent filtration, we added a Shop Vac High Efficiency Cleanstream Filter to each for approx. $20.00 ea. For maximum filtration you can get a Shop Vac Gore Cleanstream HEPA filter for approx. $30.00 ea. These last longer and are very easy to clean. Wood supports for wet/dry shop vacuums (size and design can vary based on your shop vac). Part E Dust Bin Lid with holes cut for Dust Deputys Part D (2) 5 Gal. Plastic Buckets. If you are using the above mentioned Bucket Vacs. Must be strong enough for suction of the vacuum. (1) 4 inch diameter PVC pipe 5 long (1) 4 inch diameter 90 degree elbow D Hardware and extra caulk Optional: 3/4 diameter Router Bit and Circle Cutting Jig. Exploded View 2

3 Air Box Top Diagram 1 Plan View of Air Box Top, Bottom and Sides Step 1 Cut Air Box Sides. Part A1, A2, A3 Cut three sections 17 1/8 x 3 with 30 degree angle cuts along the 3 inch widths. (See Diagram 1). Part A1 Part A2 Step 2 Cut Air Box Top and Bottom (Equilateral Triangles) Part B1 and Part B2 Cut two 18 sided equilateral triangles for the air box top and bottom. (See Diagram 1) Part A3 Part B1 Step 3 Cut Air Outlet Holes in Air Box Top. Part B1 Cut two holes (3 inches in diameter). Holes must be cut out to fit the 3 inch to 2 1/2 inch vacuum hose adapters. Use the 3 inch end of the adapter (included in kit) as a templet to draw two circles with centers approx. 4 inches apart. (See Diagram 1) Exact placement is not critical as long as they are located at least 2 from any edge. 3

4 Diagram 1 Plan View Part B2 Step 4 Cut Air Inlet Holes in Air Box Bottom. Part B2 Cut three holes (2 inch in diameter) Holes must be drilled out. Layout hole locations so the holes are 11 inches apart on center in an equilaterial triangle pattern.(see Diagram 1). The centers of the holes are nearly 4 inches from the triangle corners or points. Note: It is best to make the 2 inch holes with a 2 inch hole saw drill bit to keep the edges perfectly round for a tight seat and air seal to the top of the Dust Deputys. Part B1, B2, A1, A2, A3 Bottom View Step 5 Assemble Air Box. Parts B1,B2, A1, A2, and A3 After all five holes are made, it is time to assemble the triangular air box. The 3 sides fit inside the triangle top and bottom so there is at least 3 inches inside the air box. All edges are glued or caulked so as to provide for air tight seals. All 30 degree ends overlap. 4

5 Center Air Pipe 2 dia. holes on 4 7/8 Centers 4 7/8 Center Air Pipe fitting joins the three Dust Deputy inlets. Step 6 Center Air Pipe-Three Dust Deputy PVC connection. Part C Cut a 5 length of 4 ID (4 3/16 OD) diameter PVC pipe. Using a 2 diameter hole saw drill bit, drill three 2 diameter holes into the 4 diameter PVC pipe 120 degrees (4 7/8 ) on center. Drill hole centers at 2 from top of PVC pipe. Note: Use a Drill Press for best results. (See Diagram 2 Plan & Elevation Views) Cut 4 diameter plywood plug for top of PVC Center Air Pipe Connection. Plug fits inside of PVC pipe above the 2 diameter holes. Install and seal the plug with silicone caulk during assembly of the three Dust Deputys to the Triangle Air Box after Step 7. (See Diagram 3) Add a 4 inch diameter PVC elbow at the bottom of the PVC connection. 2 5 Part C Diagram 2 Plan & Elevation Views Step 7 Assemble the three Dust Deputys to the Center Air Pipe and the Triangular Air Box. Test Fit: Invert the Triangular Air Box so the three hole side is up. Turn the Dust Deputys upside down, put the three inlet ports into a triangular position so the 4 inch PVC Center Air Pipe (Step 6) fits inside. You will note the two inch side ports are too long and approximately 3/4 to 1 will have to be cut off of each side port on the Dust Deputy. At the same time insert the 2 inch outlet ports at the top of the Dust Deputys into the three holes of the Triangular Air Box bottom pannel. Check to make sure all three inlet ports fit the PVC Air Pipe Connection and the three Dust Deputy outlet ports fit into the bottom of the Triangular Air Box. You will note from looking into the 4 inch diameter PVC Air Pipe that the side ports are too long and will have to be shortened by approximately 3/4 to 1. Mark for cutting but do not cut too short. It is ok for some of the side air ports to extend into the 4 PVC Air Pipe, this is necessary for silicone caulking and sealing. Cut off/shorten side ports of Dust Deputys. Diagram 3 5

6 With all three Dust Deputys right side up and on a flat level surface apply silicone caulk to the three Dust Deputy inlet ports where they will connect to the 4 inch PVC Air Pipe. Insert the 3 side ports into the 4 inch pipe and further caulk and seal all around inside and out. Take the 4 inch diameter plug for the top of the PVC Air Pipe, apply silicone along the edges, insert into the pipe and caulk further to ensure a silicone tight seal. Note: Plug sits directly on the tops of the side air ports. Install the Triangular Air Box onto the three Dust Deputys and PVC Air Pipe Assembly. Seal completely with silicone caulking inside and out. Note: An air tight seal is essential for maximum performance air flow. Set the Assembly aside so caulk can set up. Let harden before assembly to base. Dust Bin Lid Step 8 Dust Bin Lid. Part D The following dimensions are for a dust bin that is 22 in diameter. Adjust diameter of plywood to fit your container. Your dust container must be large enough in diameter to fit the three Dust Deputys and to withstand the suction of the two vacuums. Note: Vacuum support shelves could be cut into this piece instead of adding latter. Design to fit your vacuums. Cut 24 diameter plywood circle. Router a 3/4 wide x 1/2 deep groove for the foam seal. For best results use a 3/4 diameter router bit and circle cutting jig. Center the router bit at 10 13/16 inch radius cut, resulting router cut should give you an inside groove diameter of approximately 20 7/8 and and outside groove diameter of 22 3/8. If you have a different diameter dust bin, center the groove to the diameter of your bin. The required foam gasket will compress the lid to the bin and form an airtight seal which is required for dust separation in the Dust Deputy Cyclones. 6

7 Step 9 Assemble to Base and Cut the Holes in the Dust Deputy Bases. Place the top assembly onto the Large Dust Bin Lid. Standard diameter is 24 inches with routed grove for foam seal. Center the bases on the three Dust Deputys so they are approximately the same distances from the edges/perimeter of the lid. Mark the six screw bolt holes and outer base of each of the three Dust Deputys. Using the supplied foam rubber round gaskets as a templet draw the circles that are approximately 3 1/8 to 3 1/4 diameter. Then cut out the three holes and drill 1/4 inch holes to bolt the Dust Deputys to the dust bin lid. Part D Test fit for the correct sizing and hole locations, then install gaskets and bolt the Dust Deputys to the lid. Step 10 Vacuum Supports. Part E Cut two vacuum support shelves, actual shape and dimensions are not critical. Cut and fit to your specific equipment. Note: Vacuum units can be held on by bungy cords, cord, velcro, straps, etc. Install 2 1/2 to 3 inch reducers at top of the Triangular Air Box. Apply silicone caulk sealent to the two 3 inch holes on top of the Triangular Air Box as well as the outer edges of the 3 inch reducer, install into holes. Apply any additional sealant if necessary. 7