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post #1 of 32 (permalink) Old 05-16-2019, 12:40 PM Thread Starter
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Default DC enclosure project

On another thread, Stick suggested enclosing the dust collection unit with an air return so that heated or cooled air is returned to the shop. Since we regularly have 30 degree winters and 105 degree summers, this idea seemed pretty good to me.

This thread will be about how I go about doing what Stick suggested, and the installation of a Super Dust Deputy.

This may take a couple of weeks to complete, so join in with any suggestions. Being an old guy, I take my time and only do a few hours a day. The project takes place in a breezeway between two sheds, a 12x25 shop shed and a 10x12 office shed. Both are wired from a shared 60 amp sub panel near the rear of the breezeway.

I put a roof over the breezeway, which is roughly 4 ft wide. The sheds are side by side, but not parallel or plumb. I used 1x6 pine to make a good floor between the two sheds. The office shed has a half door leading out to the breezeway. (At the rear of one shed is a simple stand up urinal-I'm an old guy and nearby plumbing is my friend.) Last week I extended the floor 3 feet so I can walk out the half door into the breezeway without stepping down to the dirt.

Very convenient. The sheds sit on crushed rock, contained by 2x10 planks and held in place by 24 inch long steel spikes on one side, and by 24 inch rebar driven into the ground. Redwood is used for contact to the ground. The rock is why the sheds are not quite parallel, and why the shop shed is not plumb.

The picture is of the DC unit as it was at the start. Sagging hose and all.
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post #2 of 32 (permalink) Old 05-16-2019, 01:02 PM Thread Starter
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I ordered a Super Dust Deputy (SDD) to replace my existing Rockler chip collector, which has aged and is now leaky. I will re-use the 30 gallon fiber drum, but have to cover the existing two holes in the steel lid with a 14 inch ply. Made a quick circle cutting jig by gluing a stop piece on one edge to hold it square to the band saw table. Cut a slot for the blade so I can adjust it for diameter up to 22 inches. Just used a 1/4 inch bit around which the circular piece rotates. See pix. Took very little time to make it.

I will cut a hole in the middle to mount the SDD, and seal the ply to the metal lid, then cut an additional opening in the steel lid to fit.

Sure enough, the 5 and 6 inch SDD ports are odd sizes, so had to come up with a way to fit Rocker fittings--which were slightly too large. Guy at HD used to do duct work and came up with a couple of adjustable diameter connectors that fit inside the Rockler connectors and taper down about 1/8th inch to fit the SDD. I'll bolt the metal connector to the Rockler connectors and use aluminum duct tape to seal the connections, and probably inside to smooth the air flow.

Did a little work on framing the ends of the breezeway. Very challenging since nothing, and I mean nothing, is square, parallel or plumb. Started the back opening, but it got too cold and windy to work there. The picture also shows the added deck. You can see the half door on the left, and in the foreground is a redwood box to cover part of the drip irrigation system. Yes, the door opening itself is square, plumb and parallel. The camera angle is deceiving. Need the door to seal off the enclosure properly. It will be weatherproof. Sorry for the turned picture, Maybe someone can remove it.

And for Rick, it will be insulated as well.
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post #3 of 32 (permalink) Old 05-18-2019, 10:51 AM Thread Starter
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Got busy doing stuff, off to HD for some 1x4 to frame the doorways and also to make the doors themselves. Everything's odd sized.
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post #4 of 32 (permalink) Old 05-18-2019, 10:59 AM
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Great setup Tom, I’m really liking the idea of having it outside and saving valuable room in the shop . I never thought of recycling the air back into the shop , kudos to Stick.
As for insulation,I’m not sure what that is and will Google
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I donít always insulate , but when I do .
Ok ,I never insulate
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post #5 of 32 (permalink) Old 05-18-2019, 12:27 PM Thread Starter
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Quote:
Originally Posted by RainMan 2.0 View Post
Great setup Tom, Iím really liking the idea of having it outside and saving valuable room in the shop . I never thought of recycling the air back into the shop , kudos to Stick.
As for insulation,Iím not sure what that is and will Google
I am amused.

Actually it was Stick's suggestion about recirculating AC/heated air that spurred this project. My shop is really well insulated, has good heat and AC, but putting the DC outside really does affect temperature. The air pass through back into the shop will have filters on both the outside and inside, so the recirculated air will be very clean. I'm having to do a door on each end only because there a pee place behind the sheds and at my age, that's a priority.
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post #6 of 32 (permalink) Old 05-21-2019, 11:07 PM Thread Starter
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Finished framing the end walls, tiny as they are. Very cold out there, about to have some rain (always an iffy proposition out here on the edge of the Mojave). Getting the framing square and parallel has been a chore, but they have to be to put doors on the breezeway. I'm making the doors myself with 1x4 pine assembled as if it were a face frame, then covered with ply. It will have some foam insulation inside, but I don't expect it to do much. Have to seal off one side of the floor that opens into the space under the shed. The idea is to trap the filtered, heated or AC air output from the DC, so there can't be any air leaks.

Once the doors are on and the leaks sealed, I'll open up the wall for the air return, and will use a couple of existing 20x20 filter holder grilles over them. Air will return through filters on both sides of the wall. For now, not a lot to see. Hard to do much in my present health. A little each day will do.

At that point, I'll finish mounting the Super Dust Deputy on the ply, cut a new opening on the fiber drum top, drill the fittings and bolt them into the connectors and tape it all tight. Then I can connect the flex hose, nice and short to avoid airflow loss. For that, I'll take lots of pictures in case someone else wants to do it.

Remembered doing the door framing that when I was a kid, I spent some summers helping a family friend, a good finish carpenter, hang doors. I think that's why I kind of like doing that.
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post #7 of 32 (permalink) Old 05-24-2019, 01:46 AM Thread Starter
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Rained some the last couple of days, but got the breezeway ends in place, Got the ply in place. Cut the odd shape with my Triton track saw. Nice for slightly odd sized shapes to fit the shed walls' slight angles.

Had a devil of a time getting the door casings in just right. A little off, but I can't figure out exactly what's out. The casings are pretty near right and I'm thinking maybe I'll just adjust the size and shape of the door to fit. It's off about 3/16ths. I'm going to put some gaskets in the door casings to hold in the cleaned air. I think part of the problem is that the 2x6 floor isn't quite level either. Only the top of the casing is reliably level

Cut out the opening in the plywood SDD mount (pix), and marked the six holes for mounting the SDD on to it. If you're going to do this, you need a really short pencil stub to mark the location of the holes accurately because the slanted body won't let you mark straight down with a longer one. Believe me, you want those to be placed just right.

Drilled out the holes 5/16ths, but will use quarte inch bolts with fender washers to minimize the stress on the plastic material. Will use lock nuts too.

I'm taking the top off the fiber drum this weekend and re cutting it to attach the ply ring. There won't be a lot of metal left on those tops since they were drilled for the two Rockler connectors, so I'm going to really cinch down and use some good adhesive/sealer to prevent air leaks and to help hold the lid and ply ring nice and tightly together. Also will drill and bolt the 5" to 4" and 6" to 4" connectors to the metal adapters. so they're ready to install. Now, where did I put those rolls of aluminum duct tape?

Thinking about the return for clean air. Not quite sure how I'm going to do that. Don't think I want to cut out a huge opening, so I may just cut a smaller one and attach the existing 20x20 filter holders/vent covers over them. Don't want to spend money on smaller vent covers when I have nice (expensive) ones I can reuse. They'll make it really easy to change filters now and again.

Little by little, it's coming together, and I think I'll really appreciate it when summer arrives.
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post #8 of 32 (permalink) Old 05-25-2019, 10:52 AM
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Interested in your project and how you like the end result. I have to laugh when you southern gents refer to winter in the 30s LMAO; we occasionally get to -15 here, with summer swings occasionally up to 100, but not quite as humid as you Rebs.

My similar setup is mostly completed, other than the initial connections to the D/C in the shed. The second 2.5" duct is for a three electrical circuits and compressed air.
The big difference is I will not be re-circulating the air back into the garage, in part because of the fine dust that will get thru the filters, unless you go full HEPA. I also am curious about the noise component - it is nice and quiet with the shop vac connected sitting outside, but ducting the air back in will likely bring quite a bit of the sound back inside.

For the circle cutting, I use a jig saw or router with guide, as my pre-teen sized 10" Rikon B/S is not capable of big cuts.

Nice to see you slaving away, pls carry on good sir.
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post #9 of 32 (permalink) Old 05-25-2019, 11:58 PM Thread Starter
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Moved things along today on the DC itself. First, added second row of mounting holes to the ply ring so I could position it on the lid. Pulled the lid apart, removed the connectors you see in pix 1. Will re-use the elbows with built in plumbers boots. Nice smooth curve.

Put the lid together with the ring for a trial fit and to drill the outer ring of holes to attach to the metal ring. You can see the double holes in the lid, but then jig sawed out the center hole using the ply opening as a guide. Greatly weakened the lid, but the ply will pick up the slack. See pictures of lid's process.

Next, fixing the metal adapters to the 5 to 4 and 6 to 4 Rockler connectors. A single 1/4 bolt holds it in place, but allows the metal parts to expand a bit to fit into the SDD. Pix of drilling the hole, pix of the assembled connectors, and pix of SDD with the connectors in place, but not yet taped. Will be using aluminum duct tape to seal the connectors in place, and inside to smooth out the inside airflow.

Next step is to add a layer of calk between metal top and ply ring to prevent air leaks. Need to buy a fresh tube first, something with an adhesive quality. The outer ring of six holes will get 3/4 inch, quarter inch bolts with large fender washers. Will use fender washers top and bottom to attach the SDD. Again, the idea is to reduce the stress on the plastic SDD, it's pretty sturdy, but the washers will help it along. The bottom will get a nice coat of adhesive calk as well.

My wife has an appointment tomorrow down the hill, near the Rockler. In taking the old system apart, I realized that their non-adhesive "tape" for sealing joints was good as new after about a decade. I don't like tape adhesive much, so I think I'll get some more of that tape, that is, if my wife is patient enough to wait for the store to open.
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post #10 of 32 (permalink) Old 06-01-2019, 12:33 AM Thread Starter
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Got the SDD attached to the 30 gallon drum. Have to pull everything out of the enclosure this weekend to lay in the linoleum and seal off the air leaks. Once that's done, I'll make the doors. Need to do a little fine tuning on the door framing, then finish and install the doors, and the seals around them. Going to keep the latches simple.

Happy to finally get back to this project--had a big political bru ha ha in the senior club that distracted me last week. Ended with the unpopular candidate resigning. Got a kiss from the other candidate. I do enjoy politics.
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