Building a Thien-baffle Separator (Small Dust Collector #3)

in my previous video I built this blower and in the video before the previous video I built this one pocket for my small dust collector and in this video I'm going to make the theme before separator it starts with a piece of nice 12 millimeter birch plywood I cut out a square and drilled a hole in the middle which allows me to use it as a pivot point on my bandsaw circle Jie the entire diameter of the separator has to be slightly smaller than the inside diameter of the bucket which is about 36 centimeters so I set the according radius on the jig and cut out another circle the other ring will be used later the second wall is going to be made out of clear PT plastic here marking and cutting it to length with a straight edge and a utility knife now let's cut length I can try to fit it in the groove but so far so good to mount this thin plastic on to the wood I made a mark every 5 centimeters on one side and drilled holes down then I fastened it with one screw on the disc wrap the other end around and while holding it under tension I put in another screw alright so far I only put in a few screws because I have to take it apart again anyways but what I can already see is that the plastic is a little bit too long it overlaps here by just a little bit and that's because I put this plastic under a lot of tension so now I have to cut off a thin slice again now it has the right length before I go any further with the assembly I first have to make this hole in which this piece of pipe can fit in I could just cut this hole out with disclose or jigsaw but I came up with a better solution so I cut out their majority with the scroll saw and then I made this template here with my C and C and this hole is the perfect shape for this pipe and I just going to line it up with the hole and then I'm going to use a flush trim bit and finish the hole release knock fit now if you don't have access to a CNC and make a template like this you could just cut it out close to the line and then sand until the pipe fits and that would also do the trick now to attach this ring on the bottom of the barrel I made this wooden disc that has the exact same size as the other disc so it fits in here then I can take this whole thing and put it inside the ring then I pushed on this disc and now I can put a band clamp around this ring now when I tighten the band clamp this will close the slot here and the ring will tighten against the wall okay that was the theory and I just have to do the same thing again this time with epoxy around the edge I roughed up the glue area with sandpaper to give the epoxy something to hold on to because on just a smooth plastic it won't stick as you can see here this is a slow set epoxy with about one hour of open time once all the glue is applied I remove the wedge and tighten the band clamps firmly now the slow set epoxy I use needs about six hours to fully cure but I just let it dry overnight so in the meantime I can make the inlet suit the core piece of the inlet is this round two rectangular duct transition you can find one of these and pretty much any hardware store I chose a four inch Inlet even though this will be just a small dust collector and not a big test collection unit like this one but my thought behind just was that even this small dust collection unit can handle a bigger tool like a table saw with a four inch pot and if you don't need a four inch pot you can easily put an adapter on it and use a small levels so then I made a housing in which this pipe piece can fit into it's a really simple glued screws construction but once the glue set after ten to twenty minutes I remove the screws and drill the holes larger to insert some dowels which then really give to structure some stability time post glued right and wood has been shaped okay now I can pull out this disc and there is now I have to mount the inlet oude onto the baffle and to do that I need to cut it into this round shape to cut the shape I use my circle jig on the bandsaw and I set the radius to the exact same radius of the baffle and from my 3d drawing I know where the cap needs to start and end now I just need to mount this piece on this OSB disc so I can spin it through the blade and the final check before cutting this end looks good and this end also looks good the key thing for this to work is a really sharp light that doesn't drift away from the cut because cutting birch plywood vertically is really hard work a nut sharp enough later will drift away once you enter or exits the vertical cuts so this is straight from the bandsaw let's see how it fits pretty good already I only have to refine a shape a little bit right here and after a little bit of sanding I have a really decent fit I'm going to mount in the two directly over the scene because it's not really strong and I hope that the round shape of the alleged should kind of reinforces it and when it's mounted and I cut out all these parts here then most of the weak spot parts are removed so now I just hold it down and Mark where it is okay and now with this shape I can mark all the screw hole locations and drill drilling them was quite easy but countersinking not so much I had to hold a block of wood to the other side I then attached it with two screws which hold it in place so I could pre-drill for the other screws the holes are all pre-drilled but before I attach it fully I need to cut a hole and the best tool for this I think is one of these multi tools and I again roughened up this surface for the epoxy and with an even coat of glue I then put in all the screws all righty Ella does no mountain really solid next I need to flush them all this overhang unfortunately there is no good way to do this a sharp chisel and patience are required but I took my time with this to make the transition as smooth as possible and while I was doing that I let the CNC cut out the baffle it's not necessary to use a CNC for that and a paper template would work just as good one question always is where to position the slot and I position it so that this Center here is right at the end of the inlet and from experience with my other theme baffle I know that this will work out pretty good one easy next thing to mount is this piece but the question is how when I designed this I never thought about how I actually attach this piece to the inlet so I thought about various solutions for example screwing it from the inside or gluing it in place but then I noticed that there would be a really simple solution so only two tiny screws wedged in between the wood and the plastic hold it in place really well and I can also replace this piece if I ever need to last piece missing is to pipe in the middle and there it is but I'm still not sure if these really thin walls can handle the vacuum from the blower so let's find out okay so finally I sanded everything and coated the inside surfaces as well as some of the outside surfaces with polyurethane to protect them from moisture and make them nice and smooth and now before I put it back together and test it I had an idea because this thing also functions as a really nice hat doesn't it really what I can't take this guy seriously come on okay don't yell at me for some heavy testing I have a big pile of sawdust and there it's working as I have no purpose attached yet I wore my respirator here's the view inside the bucket so as you just could see the separator works pretty good although it's not perfect because sometimes it couldn't separate or really find us and was sanctified lower but that only happened when I try to suck up really much at once which in my opinion isn't really a real world use but more of a stress test because a separator like this one works with centrifugal force so the airstream that comes in here spins around really fast in this chamber and centrifugal force pushes the dust to the outside away from the airstream of the blower and through gravity it drops through the slot into the bucket now if you suck up too much dust at once a lot of dust particles have to be accelerated at once which restricts the air flow so the whole air stream is slower and when the air stream comes in slow into the chamber it also spin slower which means less than typical force that pushes the particles to the outside bigger and heavier dust particles like wood chips aren't really affected by it because therefore the centrifugal force is still strong enough but for example sanding dust which is really really light that's more of a problem because the suction of the blower tries to pull the dust to the inside and suck it up and the centrifugal force pushes it to the outside away from the air stream but if the centrifugal force is too low and the suction is harder then this fine dust gets sucked up so what I'm trying to say is that a separator built like this with no calculations done at all has its performance limits because everything matters the size of this pipe the size of the chamber the height of the chamber the size of the inlet the power of the blower everything matters so if you calculate everything it could perform much better but with no calculation done at all you will hit some performance limits I also tried this with my big dust collector with the filters removed and when I sucked up too much at once I get the same results fine dust was blown out okay after this little bit of theory I now set up a more real-world situation so I hooked it up to my table saw so now I make a few cuts and have a look at the dust collection results separation looks good no dust coming out of the blower cutting these strips from a small board produced about this amount of dust and the separation work really well this time even though this is really fine dust because it's not too much and wasn't sucked up in about two seconds all at once which actually is a realistic usage of a small dust collector like this one all right the next piece is added to the small dust collector next thing would be your filters and a mobile base which holds all the pieces together and makes it movable but you guys said I will cover this in my next video okay that's the theory I just have to repeat the same thing with epoxy around to a around the edge the whole weak spot parts are gone yeah I could just cut it out with I could just I could just cut it I cut this I could just cut it out with the scroll saw or even jigsaw Wow straight line the core piece for you but my thought behind this was

Channel: Marius Hornberger

Views: 604,735

Rating: 4.9100833 out of 5

Keywords: wood, woodworking, holz, Holz, Holzwerken, holzwerken, Werkstatt, woodshop, shop, workshop, tools, tablesaw, table, saw, bandsaw, scrollsaw, lathe, drillpress, dust, collection, collector, Tischkreissäge, Bandsäge, drill, mini, project, projects, Projekt, video, Separator, Baffle, Dust Collector (Invention), Health (Industry), homemade, DIY, Do It Yourself (Hobby), Hobby (Interest), making, building, make, small, efficient, clean, air, cyclone, Clear, Vue, interesting, nice, cool, Good, centrifugal, blower

Id: hebWtarFp5I

Length: 14min 34sec (874 seconds)

Published: Sat Sep 26 2015