Managing dust, is my plan going to work?

Hi folks,

Newb here. I've read lots on the forum, but wow, there's so much info!
I'm setting up a workshop in the garage. Here's a sketchy drawing of how I planning to manage dust.

My shop is also used for a car and other storage. Weekend warrior.
Some machines will be on the workbench, other machines will be on mobile bases.

Based on everything I've read, want:
- 2" vac for smaller power tools, especially RO sander.
- generic 2HP 4" DC for the bigger stuff (mostly table saw)
- venting outside, especially the SV

Not too hard for my setup.
I have a window at the back of the shop, and I can run some solid or flexible duct through a board under the window. That spot is outside, under cover, in a service corridor, and there is power there. So presume I could get any old leaky shop vac with no special filtering capabilities for this purpose, it'll never come into the shop.

At the machine end, I suppose I could run a single flex hose, and connect it whatever machine I'm using one by one. Or, go a step further and install some permanent PVC ducting with blast gates (as sketched) for a bit more flexibility.

For the DC, this I'm less sure about. In the sketch, I've got it at the front of the shop, so it can be rolled outside. But it's just going to blow straight back into the shop, right? I don't work with the roller door down (it's the only access, and I like the extra light). I'd probably be better putting the DC at the back of the shop, and venting out that same window?

Anyway, am I close, or have I got this all wrong?

Cheers, -Jonny

Read the ducting recommendations sticky thread at the top of the forum
and
look at this video Understanding dust and dust removal in Men's Sheds - YouTube

Then maybe ask some more questions.

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For the DC, this I'm less sure about. In the sketch, I've got it at the front of the shop, so it can be rolled outside. But it's just going to blow straight back into the shop, right?

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Correct

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I don't work with the roller door down (it's the only access, and I like the extra light). I'd probably be better putting the DC at the back of the shop, and venting out that same window?

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Yep.

But If you are just going with a stock 2HP DC and 4" ducting I would add some forced ventilation.

Dr Bob, an enormous thank you! You're incredibly generous with your knowledge. I don't think there was a thread on the forum that I read, that didn't have your fingerprints on it. :)
The video was very informative also. Thanks.

So, here's a few thoughts and questions based on what I learned:

DC at the back of shop, and vent the exhaust out the window. That's definitely gonna work best. If I do this, does the unit need to be enclosed at all, or is that only recommended for leaky shop vacuums?

I can see from your video that a great setup would be 6" ducting, with 6" bell mouths at point of collection, and some 2" flexy for hand power tools. A smaller scale version of that might work for me. I could have a single run of ducting running front-to-back of the shop, right up the middle of the ceiling. Then I could have a few y-piece connection points, and run whatever I want off those. Would be handy to have it all suspended from ceiling and off the floor. Would that need a biggish DC to run, like 3HP+? I'm okay with that if it means I can skip on buying a shop vac and seperate 2" ducting. But, I have heard others saying hand power tools with 2" connection to DC isn't as effective as connecting the vac.

The 6" thing is a bit of a pain. I don't really want to spend loads of time modifying machines to accept 6" connections... That put me off this option in the first place. So originally, I'd thought that I would just do short runs of 4" flexy to the few machines that need it (table saw and bench top thicknesser), connected directly to DC. And put everything on 2" with vacuum at other end.

Maybe the most sensible thing is to try 6" system first. There are obvious benefits, like being to have 6" collection at table saw blade, as well as the cabinet. And if this doesn't work out for power tools connected with 2", then I can always build an enclosure for a shop vac, and vent it's exhaust back to the DC, just like a saw in one of your diagrams.

Wow, things are so much more complicated than they first seem!

Thanks once more for the awesome info you've already shared. :)

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Originally Posted by rogerwilco

. . .So maybe best compromise would be to put the DC inside, at the back of shop, and vent the exhaust out the window. If I do that, does the unit need to be enclosed at all, or is that only recommended for leaky shop vacuums?

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Enclosing the DC is definitely worth it and it will be better also in terms of noise.

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I could have a single run of ducting running front-to-back of the shop, right up the middle of the ceiling. Then I could have a few y-piece connection points, and run whatever I want off those. Would be handy to have it all suspended from ceiling and off the floor.

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:2tsup:

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Would that need a biggish DC to run, like 3HP+?

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6" ducting will requires either a 3HP or a modified 2HP DC, modified according to the sticky at the tope of the dust forums.

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I'm okay with that if it means I can skip on buying a shop vac and seperate 2" ducting. But, I have heard others saying hand power tools with 2" connection to DC isn't as effective as connecting the vac.

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If the power tool has a fan, eg sander or electric planer then the fan limits what gets through the tool os a DC connection will work just as well. OTOH, there's no fan eg router or circular saw, than you will unfortunately need a vac!

For weekend warriors the cheapest initial solution is

2HP stock DC
4" ducting to collect chips and some fine dust - but still enclose the DC and vent it outside - that will get rid of some fine dust.
Forced ventilation 2 - 4 bathroom exhaust fans, that also vent outside. and run from the moment you start making dust till you leave the shed for the day.

It depends where you see yourself going, if you start getting into larger belt and drum sanders you will be sorry you did not start out with 6" ducting and 3HP+ DC, table saw also works better with 6" ducting.

I went though this pain myself over about a 10 year period.
1HP DC and 4" ducting :((
2HP and 4" ducting :doh:
3HP and 6" ducting :D
now have 4HP and 6" ducting :cool:

Ok, I think I'll go straight 3HP twin bagger, with 6" inlet.
I will still need a seperate vac I think, for circular saw, SCMS, and other fanless stuff. Not a big deal.

One thing I'm really confused about, is how to vent the DC enclosure. Is the idea that the enclosure itself is basically airtight, and you duct the entire enclosure (not the motor itself) to outside?

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Ok, I think I'll go straight 3HP twin bagger, with 6" inlet.
I will still need a seperate vac I think, for circular saw, SCMS, and other fanless stuff. Not a big deal.

One thing I'm really confused about, is how to vent the DC enclosure. Is the idea that the enclosure itself is basically airtight, and you duct the entire enclosure (not the motor itself) to outside?

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Originally Posted by rogerwilco

One thing I'm really confused about, is how to vent the DC enclosure. Is the idea that the enclosure itself is basically airtight, and you duct the entire enclosure (not the motor itself) to outside?

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Yep, if you want to reduce the amount of noises escaping you might need a baffled exit (eg S shaped)

How much space do you have in your 'service corridor'? It sounds like the ideal place for the DC if you can manage it!

Service corridor is a no go. There's probably enough space... but it's on a steep incline, the ground is just compacted sand, and the under-house access is in the way.
It'd be possible, but messy, and a lot of work.

Instead, I'm going to enclose it, like this.

Attachment 482579

It's hard to picture what your service corridor looks like, but the point is that if you can suck your dusty air outside somewhere where it can't harm you (and of course neighbours etc) then you don't need to filter it, so you don't need a ton of gear out there. The fan could mount to the board beneath the window and discharge straight into a bin, saving you the trouble of building an enclosure and losing workshop space.

Obviously you know what is or isn't feasible there, if you need to have the DC in your workshop then so be it. It's up to you how far you go with any enclosure. It can reduce the noise (and recirculating airborne dust if it's vented outside), but I think the thrust of all the advice in the stickies is that whatever the setup, you won't make the air entirely safe with dust extraction alone, so you should still wear a mask.