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.
The more I do, the less I accomplish.
Last edited by DesertRatTom; 05-26-2019 at 12:05 AM.