Place the pipe and plywood inlet assembly, and place it on top of the baffle assembly.Form an “L” by screwing the 5” x 6” piece with the hole in it to the 5” x 8” piece of plywood.If not, you may want to add some hot glue to hold it in place. Mount the 9” length of DWV pipe in the hole by sandwiching the two halves of the DWV coupler around the plywood.NOTE: This will be easier if you start with an oversized piece, then trim it to the final size. If using different pipe, adjust accordingly. Cut a 3 ½” hole in a 5” x 6” piece of plywood.Cut the two DWV couplers in half just to one side of the inner seam.Cut two pieces of DWV pipe, one 6” long and one approximately 9” long.For best results, watch the video before attempting this part of the project. The inlet needs to be cut to match the curve of the side walls, and any gaps will result in pressure loss and a sloppy joint that requires a lot of hot glue to seal. This is easily the most difficult part of the project and requires a good deal of finesse. Plunge Router with 3/4" straight plunge bit and circle cutting jig įor links to the tools used in this video please visit.However since it’s difficult to cut a perfect circle with a jigsaw, you should cut outside the lines and then sand everything to fit. If you don’t have a bandsaw, you can still complete the project using a router, jigsaw, or even a table saw. There are plenty of ways to cut circles, but a bandsaw or router with a circle-cutting jig are two of the easier ways to do it. You will be cutting a lot of circles in this project. ~18” of 3” DWV Pipe to form the entry and exhaust ports.I recommend that you buy more than you need and cut it to fit during assembly. 18" circle of 1/8" MDF to form the bottom baffle.Small plywood pieces measuring roughly 5” x 6”, 5” x 8”, and 2” x 8”.Note: If you use the method I use in the video, you can simply use the inner portion that remains after forming the bottom ring as the top.16" circle of ¾” plywood to form the top.20" circle of ¾” plywood to form the base.Rubbermaid 20 gallon roughneck trash can.If you are using a different collection vessel, you will need to alter all of your measurements to fit. IMPORTANT: The measurements below are tailored to fit the trash can I used. When used with a shop-vac, this simple dust collector will greatly prolong the life of your filters and prevent the constant need to empty the vacuum bin, which is typically small and difficult to remove. When driven with a blower like I use, the baffle removes the need for a standalone dust collection system (which not everyone has the money, space, or power to accommodate). It works because the incoming air is forced around the outside wall, where the heavier dust and chips fall into the large trash can below. This is an easy-to-build dust separator with a baffle.
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