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  1. #1
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    Default Thien Baffle Dust Extractor

    After firing up my router for the first time the other day, it immediately become obvious that I was going to need to find some way to remove the sawdust from the work area.

    I was pointed towards the Thien baffle design, and doing a quick bit of research it looked liked something I might want to try trackle myself to save a few dollars.

    So a quick trip to Bunnings to scout for parts and $60 laters I walked out with the makings of my first dust extractor.

    I already had the MDF from some cover sheets I bought cheaply, and some 12mm MDF I bought (at full price) to make templates.

    The following is a photo log of my efforts...

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  3. #2
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    Default

    Not a lot of progress tonight as I had to go out for dinner...

  4. #3
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    Default

    Based on my experience, I'm sure you'll find this to be an excellent addition to your workshop. I made one that's very similar to yours - it's great.

    cheers,

    ajw

  5. #4
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    Thanks ajw looking forward to having it finished so I can get on with what I built the work bench and the dust extractor for... my new speakers.

    Anyone know how to make a MDF Oreo??? like this (see pics)

    Nearly there, had to use a few long bolt I had laying around to mock up the top piece. Considering just getting some more long bolts rather than cutting threaded rod to size.

    Those with a keen eye will notice that I re-routed the holes near the edge to sit the right angle bend in further and to reduce the gap between the bottom plate and the lid.

  6. #5
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    All bar finished it tonight. Just have to buy a vacuum and some hose, glue in a few adaptors and it's ready to go. All up took about 10hrs to build and about $70-$80 so far in parts.

  7. #6
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    G'day headscratcher, I notice you have a reducer on the vacuum connection on your dusty and are going out to buy a vacuum.
    I'm no expert but have you given any thought to the effect that reducer will have on your system.

    There are basically two types of systems in dust collection. Vacuum cleaner based which use high speed, low air volume to work and high volume low speed systems most commonly sold as dust collection machines from your local woodworking store.
    The problem is you can't mix the two. If you use that reducer on the system I believe you will be disappointed.
    Check it out before you shell out for the vacuum, you probably need a bigger volume impeller based machine to run that bucket.
    Cheers, Ian
    "The common law of business balance prohibits paying a little and getting a lot.. it can't be done.
    If you deal with the lowest bidder it is well to add something for the risk you run.
    And if you do that, you will have enough to pay for something better"

  8. #7
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    Looks great. I wouldn't mind having one of those in my shop.
    I agree with Nanigai the reducers are likely to lead to inefficiencies.
    My blog: ~ for the love of wood ~ - http://theloveofwood.blogspot.com/

  9. #8
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    Quote Originally Posted by Nanigai View Post
    Check it out before you shell out for the vacuum, you probably need a bigger volume impeller based machine to run that bucket.
    Cheers, Ian
    That dust separator will kill a DC. For a start the connections are way too narrow and just the design of it will consume more than 1/3rd of the pressure generated by even a 2HP DC. Small dust separators are really limited to the small flows generated by a vacuum cleaners.

    More significant than anything is what sort of vacuum cleaner is going to be hooked up to it and if it is a non-genuine HEPA where is the air going from that vacuum cleaner. If it's going out into the shed it will do nothing for invisible dust removal except fill the shed up with fine dust. Not many people realise that cheap vacuum cleaners actually make more invisible dust than they pick up.

  10. #9
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    Nice work HS.
    That will certainly keep the workshop a lot cleaner. I have a Clearvue one and it does a great job.
    Those were the droids I was looking for.
    https://autoblastgates.com.au

  11. #10
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    Default

    Thanks for the comments guys but nothing is locked in stone at the moment. I went back to Aldi where I saw Wet/Dry vacuums advertised the other day, but they were all out when I went back. (thought I saw some mention of HEPA)

    Couple of problems I have encountered so far... the first one is that I am finding it hard to get suitable hose that is bigger than about 40-50mm to collect the sawdust. Bunnings only seem to carry the larger sizes in hose that has holes all through it.

    So suggestions where I can buy 90mm or bigger hose in Sydney welcome.

    Second problem is I really don't know what sort of vacuum I should be buying... I want something that is cheap as possible that does the job.

    I have even considered getting one of those electric fan things that are quite large, I don't know their proper name.

  12. #11
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    Quote Originally Posted by HeadScratcher View Post
    Thanks for the comments guys but nothing is locked in stone at the moment. I went back to Aldi where I saw Wet/Dry vacuums advertised the other day, but they were all out when I went back. (thought I saw some mention of HEPA)
    Be careful, there are lots of fake HEPAs around. I have never seen a cheap genuine HEPA.

    It's a waste of dust collection power to connect a DC to a small pipe and Vice versa for Vacuum cleaners.

    DC's are high volume low pressure devices connecting them to narrow ducting kills their performance. They need big ducts to work properly. But not too big or the airflow will be so low the dust will fall out of suspension

    Vacuum cleaners are high pressure low volume devices. Connecting vacuum cleaners to large ducting is just the same as connecting DCs to ducting that is too large. Vacuum cleaners work well OK with some power tools with specifically designed dust extraction shrouds but unless they are genuine HEPA.

    I reckon cheap vacuum cleaners are hopeless as far as invisible dust is concerned. The only thing they are good at is keeping the shop looking visibly clean.

  13. #12
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    Can you point me in the right direction of what I should be looking for? I have only ever used a vacuum, so even though I now know I need high volume low pressure I still don't know what that looks like as a product. I need steering towards what I do need.

  14. #13
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    Quote Originally Posted by HeadScratcher View Post
    Can you point me in the right direction of what I should be looking for? I have only ever used a vacuum, so even though I now know I need high volume low pressure I still don't know what that looks like as a product. I need steering towards what I do need.
    Have you read the FAQ sticky - just above this post?

  15. #14
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    Read it and didn't find the answer to my question... pages and pages of why dust is bad for you, but no hint as to what the device you suck it up with is called.

    Decided I have wasted enough time trying to suck the dust up, I am just going to blow the dust off the job so I can get on with my project

  16. #15
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    Headscratcher, a high volume low pressure system is what a generic dust collector is, something like this Jet® Dust Collector 1/2HP - Rockler Woodworking Tools This is what is known as a single stage system. There are varying types, some with bags, some with filters and in general they are good for picking up the chips but not a lot of the dangerous dust generated while machining wood because they do not have the capacity to pump enough air. The manufacturers of this typ of machine tend to fudge the figures and not let the truth get in the way of a good story. This type should always be isolated from the work place so that all the exhausted air does not re-enter where work is happening. The bag type leak so much dust that you are literally recycling the dust if it is in the same work area as yourself. The ones using filters while better leak the very fine dust and the filters clog quickly thus impairing performance of a machine that was not the best in the first place. The more powerful of this type and the linked on is not one of those, when isolated from the work place and ensuring the exhaust cannot re-enter the workshop can do a good job when used with correctly designed ducting.

    A better but more costly system is a cyclone, far more capable of moving a lot of air and generally doing a better job if it is designed correctly but some aren't. A good cyclone will separate dust to such a degree that for all intents and purposes the exhausted air and what dust there is will quickly disperse in the air. Some users do have filters on cyclones but that is not common in Australia. The only reason to filter a cyclone is if you have heated or cooled air in your workshop and do not want to lose that air by exhausting outside. The advantage of a cyclone is its (generally) superior performance and due to its ability to separate to a figure of around 99.5% of the debris and dust collected the exhaust is far cleaner. The cyclone also does not need to be isolated from the work space as it can be exhausted outside through ducting.

    Both above types to be effective have to utilise 150mm ducting and it is this requirement that the less powerful machines of either type fail badly on as they cannot support the required air flow. This point is addressed in the above FAQ.
    CHRIS

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