Dust collection - Do something about it... - Page 4 - Router Forums
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post #31 of 35 (permalink) Old 05-11-2019, 12:48 PM Thread Starter
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Expecting arrival of the Super Dust Deputy (SDD) today. There isn't much solid information about inside and outside dimensions for the SDD and adapter sizes. The Amazon recommended reducer does not fit, but the Rockler dust rite adapters may, but I'm going to carefully check it out before I spend any money. I haven't decided for sure, but I'm thinking of going with Galvanized pipe from the SDD to HF unit. The problem again is that the 5 inch opening on the HF unit doesn't seem to fit anything else exactly. So I'm going to do some exact measuring and try to use standard galvanized pipe and fittings.

I really liked Stick's suggestion to recycle the filtered output of the HD/Wynn filter back into the shop. So I plan to do that and put a couple of filters in the return to eliminate any wandering dust. I will also have to enclose the breezeway with doors on each end and sealed as well as I can. I'll also cover the small gaps between the 2x floor in the breezeway with linoleum, to seal it and make it easier to clean up. Need to keep the AC/heated air in the space, so I may also insulate the ends as well, which will bean thick doors.

At any rate, I promise to post measurements, part numbers, pictures in a new topic. In some ways, I'm not looking forward to getting those fittings right, I have a box of expensive DC parts that don't fit anything. I have a couple of rolls of aluminum duct tape standing by.

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post #32 of 35 (permalink) Old 07-15-2019, 07:51 AM
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The last entry to this thread is a couple months old, but I'll chime in anyway since this is germaine to the larger discussion and, likely, something that everyone at some point in time will need to address.

I have become increasingly aware over the past few years (especially with my career change) of the cumulative effects of dust/smoke damage to the lungs. Now that I'm in my 50s, I think I've played Russian Roulette long enough that, if I want to avoid COPD or other such hazards, I need to be more careful.

I have also become more active in my woodworking since settling into the new career/job as well as my kids growing and moving on to their own lives. I noticed that, after a particularly aggressive woodworking session, I would end up sneezing/coughing for a significant period of time after I closed down the shop and cleaned myself up. The dust was a problem. I was covered in it and had been breathing it in.

Well, the external "big" dust is one thing: Wear an apron, wear a mask (I got an RZ mask). But even still, there was still dust EVERYWHERE.

My original DC was a HF 110v unit, no mods. This was, in the parlance of advanced dust collection and filtration experts, "piss poor". After the collection power of this unit became effectively nil, I looked into the wisdom of "the google" and found "the modifications" which I will not discuss here in depth since everyone knows them already or they can read about them in the 4000+ references that are easily findable with a search. Fine (and not so fine) dust was, frankly everywhere. The unit by itself was mediocre at picking up "wood chips and shavings", but ... Well.. Not good at anything else.

I tried the dust deputy solution with a Wynn 13F230NANO filter. I did NOT do the impeller upgrade. [I felt like, frankly, I was throwing good money at a bad machine with what I had done already (for some folk, this HF machine is fine. I'm not one of those folks).] Performance was better, dust capture was somewhat improved, but still not acceptable by the standards I was trying to reach. Fine (and not-so-fine) dust from the machines was still a problem because the vacuum power of the HF unit for what I was trying to accomplish just wasn't there.

You may ask why didn't I do the impeller upgrade and squeeze a little more out of the already frankenstein-inspired modified HF unit? My theory is that for the money I invested in the machine and associated upgrades to get a mediocre solution, I could find something for about the same money that would actually perform. I also do not subscribe to the "sunk cost theorem". In another sense, why try to solve a problem (with multiple, incremental changes to a product not designed to do what I needed) that has already been solved?

Enter: the Grizzly G0440. $600 on Craigslist. 100 hours or so on the machine. Squeaky clean. I am using the Wynn 13F230NANO filter (230 s.f. of MERV 15 surface area) on it instead of the supplied filter (90 s.f. of MERV 9-10 filtration) which greatly reduces the fine dust return to the shop and greatly increases the machine's ability to "breathe". This unit will be in an enclosed room with extra filtration on venting.

The G0440 is a significant upgrade performance-wise from anything the HF unit can provide and pretty much eliminates the "poor vacuum" issues that I was having. The first test of the machine on my saw caused a bit of a stir -- it pulled dust from places I didn't know could have dust in them! I tried running the machine just to filter air and noticed after a few minutes that the particulates seemed to be down. I do not have a particulate counter, so cannot provide objective data. However, I wasn't sneezing and coughing anymore and the "smell" of dust in the air was gone.

This (the new DC) isn't a solution in and of itself. There are many components to managing the problem (e.g. face mask, adequate ventilation, adequate filtration of particulates), but the dust collector is potentially the first issue to be addressed in a shop when it comes to dust management and air quality. If you don't have adequate LARGE dust collection, then you definitely do not have adequate SMALL/FINE dust filtration.

I am NOT trying to crap on the HF unit. As I stated, for many folks, this unit is fine for their needs and will perform. It is inexpensive and easily managed. Larger units are more difficult to deal with in a small shop (power, space, ducting).

YMMV, some settling may occur during shipment, get your parents to help you with assembly, don't run with scissors, always eat your vegetables.

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Seabrook, TX
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post #33 of 35 (permalink) Old 07-15-2019, 09:41 AM
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That is the problem with the cheap units is that they merely redistribute the fine dust as mine does and up north having it on the outside of the shop is not an option. I suspect that we'll see DCs go through some major improvements in the future probably spurred on by agencies like OSHA and the Worker's Compensation Boards. Cheap units like the HF will probably still be available but will come with a disclaimer attached. There was a time when no one would have thought that you wouldn't be able to buy packaged food that doesn't have how much fat, sugar, etc is in it.
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post #34 of 35 (permalink) Old 07-15-2019, 11:46 PM Thread Starter
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Since this string was published, I've followed Stick's recommendation with a shop modification. There was about a 4 ft space between my shop/shed and my office/shed. I covered it, put in a floor, covered the floor with linoleum and built doors on each end. In other words created an air tight chamber, that I can open up if needed.

The DC and the the Super Dust Deputy went inside. The SDD sits on the 30 gallon chip collector. The 4 inch hose inside moves from machine to machine, including the table saw, and that terminates in a Rockler through the wall 4 inch connector. Outside, in the chamber, the sawdust is sucked into the SDD, and almost all the dust and chips fall into the fiber drum. A 4 inch connector on top of the SDD, goes into the HF unit, then the air is filtered and exits through the Wynn filter.

I cut a hole for a return of air into the shop. to preserve temperature there. The return hole has a 20x20 filter so the returned air is very clean. Even with all that, I also have a WEN air filtering unit hanging from the ceiling that runs for 1,2 4 hours on a timer and slowly removes all the smallest particles.

The final tune up was arranging the parts so I could minimize bends in hoses for greater air flow.

Pix shows all but the entire setup, you can see the 20x20 filter box in the wall at upper right. The long hose has been shortened to about 18 inches since this picture was taken. Note the linoleum on the floor, which keeps air from escaping there.nnn

The challenge was getting the structure squared for the doors, both shed walls are not parallel to each other, but I finaly got it squared up.
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post #35 of 35 (permalink) Old 07-16-2019, 10:23 PM
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Well done Tom.

Jon
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