Updated 17/9/09

Serif - WEBPLUS X2

The answer was to have a centralized dust and chip collector and a network of ducting and hoses connected to each of the machines, via blast gates - the type of thing that most home woodworkers have. The length of the hoses (4") were quite long, with numerous joints and elbows, which reduced the efficiency of the system dramatically, I also noted that whilst planing wide boards (15") the protective grill (to stop large chunks of material hitting the impeller) was getting continuously clogged by these wide shavings. The noise and dust generated by the collectors running was quite tiring and detrimental to my health (no 1 micron bags available here)

Over time, the amount of dust and chips I produced has increased as I moved away from using hand tools and increased my collection of big machines in my small workshop. I found that I needed a minimum of two dust collectors (1/2HP & 2 HP), otherwise I was constantly having to move the dust collectors from one side of the shop to another.

My available space was getting smaller, noise and dust increasing - there had to be a better solution - I looked in lots of magazines and on the net - the answer seemed to be a cyclone type collector, but as my ceilings were only 6' 10" high I would have a problem to install one (plus the high expense of shipping and a motor change), then I came across an article about 2-stage dust collection. This seemed to be the answer I was looking for, so I quickly made up a simple box along the lines of the shown below, but much smaller, just to see how it would work - the efficiency was reduced slightly, but the problem with clogging was eliminated totally and the dust particle problem was severely reduced.

Heavy and larger particles drop into the large box, whilst the fine dust only is processed through the dust collectors.

I then read an article about placing two Dust collectors in Parallel to increase the "suck" (both dust collectors should be matched in size and capacity, so they do not fight each other), so a I bought another identical 2HP dust collector - I thought why not incorporate them with a larger 2-stage dust collector and at the same time remove a lot of the 4" flexible hoses and replace them with 6" steel ducts - and move the whole extraction system outside and build a waterproof lean-too to house the system in (a lot of work, that has rewarded me many times over).

That was 3 years ago and the system is working great, I can have up to 3 machines collecting dust at the same time (if I forget to close the blast gates), the noise of the dust collector motors is not heard at all, just the leaking hiss of vacuum when the blast gates are not closed properly, or a damage flexible hose. no more fine dust from the dust collectors, no more clogging - and extracting to the outside, seems to make little or no difference to the temperature inside.

Very simple system, which saves a fortune on buying a cyclone. 3/4" MDF, glued and screwed, a couple of old Chipboard doors (wardrobe). the system has no protection (varnish/paint), the outside humidity does not seem the be affecting the material.

Every time I open the doors I get a different picture - this is the collection box - 0.78m3 (206 gallons/27.5'3) when full, depending on the work load anything from a week to a couple of months between emptying the system. The plastic bags get emptied at the same time, but are never more than 1/8 full, this is with the very fine harmful dust, that was a big problem before.

If anybody wants the precise measurements and angles used, just e-mail me and I pass the information on to you.

The two matching 2HP dust collectors - I plan this year to try and increase the efficiency of the system, by raising the motors of the ground and placing them much closer to the 5" ports, thus eliminating about 6' of flexible hose in each DC and some radii.

2-Stage Dust Collector