I started with a 1hp blower and a bag. No solution there! Went to 2 hp and a bag, then added a Rockler chip collector setup. Inadequate.
Finally gave up after having spent hundreds of dollars on connectors, hoses, barrels, and other gadgets, none of which really worked all that well.
A couple of years ago, I found that Harbor Freight had their 2hp DC on sale, with a coupon for about $150. I bought one for my shop, and ordered the Wynn filter for it. It has a Rockler 4 inch hose that I move from tool to tool. Some tools with a 2.5 inch port, I've added a 4 inch fitting to the small hose and just drop it into the long 4 inch hose.
That combo with a chip collector before the HF unit, has all but ended my sawdust problems in the shop.
I also have a partial shop in my garage, so I got another HF unit, on sale most holidays, and have it in the garage with the same chip collector. Kept the bag filter because I can just roll it outside for use. I also wear a mask.
If i were to change one thing, I think I'd switch to a Dust Deputy for the chip collector, but the 4 inch model costs more than the HF unit. I'm a throat cancer survivor so I take the warnings about sawdust being carcinogenic seriously.
You can order an impeller from Rikon to replace the one in the HF unit. Takes a little jiggering to make it fit, but it supposedly greatly improves air flow. I can't recall who on the Forum did this, but it was a tight fit, but otherwise successful.
I looked at many name brand options, but for me, on sale HF units are just hard to beat. If the motor failed, I could just buy another unit for less than the price of a good replacement motor. With the chip collector, there's not many pings and dings for the plastic impeller.
Add to that a ceiling mounted dust filtration unit. I have two WEN units, which are 1/6th horse power, double filter units with a timer and speed controls so you can leave it on after you leave the shop and have it clear the fine particles in the air. I found the last WEN unit for just over $90 through WalMart's online/store delivery system. It is available on Amazon as well.
Next up for me is adding an above the blade collector for the table saw, and a small scoop-like piece just behind the blade of the worst dust offender, the sliding miter. The sliding miter is surrounded by a clear shower curtain, gathered in the bottom into a 4 inch connector, with a short hose that connects to the long DC main hose. I taped this together using aluminized duct tape.
All my cabinets and shop stands have doors and backs on them. Othewise they gradually fill up with sawdust. Doors really help. And all shop stands are on casters so I can move them around for cleaning. In a tight shop, sawdust finds lots of hiding places and then sneaks out in the air when you walk around the shop.
A detail: 4 inches isn't 4 inches, depending on the hose and connector manufacturer. Different makes don't play together well, so stick with one brand. It took a little while, but Rockler's Dust Rite connectors and hoses seem to be consistent and fit together well.
Even with all this, I keep a box of disposable medical style masks that I put on most of the time I'm in the shop. I guess I'm really a suspenders AND belt kind of guy.
HF 2HP with Wynn 1 micron steel filter drum.
Fiber drum Chip collector with Rockler connectors.
The more I do, the less I accomplish.
Last edited by DesertRatTom; 05-07-2018 at 05:33 PM.