Super-charge Your Shop Vacuum

Transcript

Super-charge your Shop vacuum © 2012 August Home Publishing Co. best-built jigs & fixtures supercharge Your Shop Vacuum A low-cost cyclone kit and this simple cart turn a shop vacuum into a top-notch dust collector. A shop vacuum comes in handy to collect dust and chips from power tools and for all-around shop cleanup. But it doesn’t take long for the filter inside the canister to clog with dust, which reduces its effectiveness. To prevent this from happening, Oneida Air Systems designed its Dust Deputy kit shown above. It features a small, plastic cyclone separator to direct most of the 1 WoodsmithPlans.com SN10936 dust and chips into a five-gallon bucket. The kit shown in the photo on page 2 includes a gasket with hardware and an extra bucket to attach the cyclone directly to the side of the vacuum canister. As the bucket fills with chips though, things can get unbalanced. So I designed the roll-around cart shown above to create a stable, compact dust collecting center. ©2012 August Home Publishing Co. All Rights Reserved. Exploded View Details OVERALL DIMENSIONS: 351⁄2"D x 17"W x 413⁄4"H rack corrals hose when not needed vacuum attachments slip over dowels in rack hose connects shop vacuum to top of cyclone collector hose fits into side of cyclone accessory rack holds commonly used shop vacuum attachments Hinged cover holds cyclone in place yet flips up to allow you to empty bucket slot in back accommodates 2!/2" hose connecting shop vacuum and cyclone cut-out handle makes it easy to move the collector anywhere in the shop recessed platform keeps shop vacuum stable and secure Funnel-shaped cyclone separates dust and chips from airstream and into collector bucket collection bucket rests in recess in base of cart large casters easily roll over power cords and debris Materials & Hardware {  Oneida Cyclone Kit. The Dust Deputy kit includes the cyclone, two buckets, mounting hardware, gasket, and connector hose. 2 A B C D E F G WoodsmithPlans.com Bottom and Rim (2) Sides (2) Top (1) Shelf (1) Back (1) Attachment Rods (2) Cover (1) SN10936 17 x 351/2 - 3/4 Ply. x 25 3/4 - 3/4 Ply. 41/2 x 14 - 3/4 Ply. 41/2 x 121/2 - 3/4 Ply. 14 x 36 - 3/4 Ply. 1 x 1 - 61/2 1 9 /4 x 14 - 3/4 Ply. 41/2 H Hose Holder (1) 9 x 4 - 41⁄2 Ply. I Holder End (1) 9 x 9 - 3/4 Ply. • (4) 3" Swivel Casters w/ Screws • (28) #8 x 11⁄2" Fh Woodscrews • (7) #8 x 3" Fh Woodscrews • (1 pr.) 3" Utility Hinges w/ Screws • (1) Dust Deputy Cyclone Kit ©2012 August Home Publishing Co. All Rights Reserved. B C D roll-around E F G H AA BB C C D D E E F F GG H H I I J J K K L L MM N N O O P P QQ R R I J SS T T UU V V WW X X Y Y Z Z K L A AA B BB C C C D DD E E E F F F M N GGG HHH I I I J J J K K K L L L O P R this simple Q QQ R Rof P P Ppurpose OOOmain MMM NNNThe Q R is to platform X V WWW Xa Xsingle V Vprovide U UU S SS T T Tcart T Z Z Z for both a shop vacuum and Sthe YYY CL Dust Deputy system. But you’ll Ufind V Cart 3 1 14 RIM A FIGURE 10!/2"-DIA. HOLE 6!/4 2" RAD. 3 3" RAD. CL 10#/4 there are a few other features as W X 6!/4" RAD. a flip-up cover OVERALL DIMENSIONS: Y Z 3" LOCKING adds stability to the tall, slender (24!/2" x 24!/2" x 24!/2") PART NAME SWIVEL cyclone. Pulling on the hose could CASTER A B CALLOUT PART NAME w/LETTER cause (first time used)the cyclone to tip over withC DA TOP VIEW out this extra support. EBOTTOM F SIDE VIEW NOTE: ALL Another feature is the center col(17" x 35!/2") PARTS ARE G H AA one HH I I C C Dthere’s BB side, D E E aFrack F GGfor RIM #/4" PLYWOOD umn. On P QQ R R M N N O O Pused K LL M I J storingJ Ja Kcouple commonly X Y Yon SS T T UU Z Z And dueKto Lits straightforward joinV V WW XThen shop vacuum accessories. C D DD E E E F F F C C AA B A BB M Nbuild it and put it to use the other side, there’s a rack that’s ery, you can END VIEW GGG HHH I I I J J J K K K L L L O P designed to hold the vacuum hose. in just a weekend. #8 x %/8" Ph MMM NNN O OO P P P Q QQ R R R WOODSCREW SIDE VIEW Additionally, Q R the rounded base X X X S SS T T T U UU V V V WWW stable base won’t Ycatch or workS T Z Zyour tools Y Y Zon CL TOP VIEW bench. And the large, 3" casters I began Ubuilding the cart from the (CROSS SECTION) V aren’t likely to get caught on power base up since all the other parts are Two-Layer Base. The base STEP 1: XXXX cords EXPLODED or cracksAin Bthe VIEW floor. attachedWtoXit. The base is sized to actually consists of two different XXXXXXXXXXXXXXX OVERALL D is made from hold theYcyclone, Z Finally, the CDIMENSIONS: cart bucket, and vac- layers of plywood. The first layer FIRST: XXXXXXX (24!/2" x 24!/2" x 24!/2") PART NAME E F XXXXXXXXXXXordinary, inexpensive plywood. uum, as shown in Figure 1. is solid. The second layer has a CALLOUT PART NAME w/LETTER pair of cutouts. E F F XXXXXXX G Hused) AA BB C C D D ENOTE: GG H H I I (first time A FIGURE XXXXXXXXXXX 2"-DIA. TOP VIEW The cutout on one end captures J J K K L L MM N N O O P P QQ R R I J TOP VIEW D the five-gallon cyclone bucket. On X YY ZZ SS T T UU V V W"INCH W X MARKS" K L E 2 D DD E E E F F F C the other end, the cutout creates a C A AA B BB C “QUOTE MARKS” M N BACK K KHK L L L HHHH HI I I I I J J J G (14" x 36") E EGGG F F GG rim to keep the shop vacuum from FO P FRONT VIEWR R R 2!/2 MM N NMO R R P P P QI QQ O PNPNNQQO OO rolling off the base. F J 2!/2 ATTACHMENT Q R #8 x 1!/2" Fh ROD X X X WW C X YT YT TZ ZU UU V V V W WWS XSS To create the cutouts, I started WOODSCREW K L (1" DIA. x 6!/2") L END VIEW S T Y EZEZ FZF F YYE D DD M N by cutting two rectangular blanks TOP U V J J J K K K L L L TOP at the table saw to match the width O P SIDE VIEW 2" DIA. 3!/2" P P P Q QQ R R R 2!/2 3!/2" and length shown in Figure 1. Q R W X 5 DIA. DIA. CL V WWW X X X VIEW V VEXPLODED TOP VIEW B I set one of the blanks aside for OVERALL DIMENSIONS: CL Y Z (CROSS C SECTION) (24!/2" x 24!/2" x 24!/2") S T the time being and marked the TOP PART NAME F U V 5#/8 (4!/2" x 14") TTACHMENT STEP 1: XXXX CALLOUT location and size of the cutouts SHELF PART NAME w/LETTER XXXXXXXXXXXXXXX W X 1#/4 on the other blank. The cutout TOP VIEW EW (first time used)D FIRST: XXXXXXX IONS: Z for the shop vacuum is sized to Y XXXXXXXXXXX !/2") D 12!/2 PART#8 NAME accommodate most models, but x 1" Fh SHELF NOTE: XXXXXXX WOODSCREW (4!/2"XXXXXXXXXXX CALLOUT x 12!/2") it’s a good idea to check the overall CL TER B #8 x 1!/2" Fh “footprint” of your vacuum before TOPWOODSCREW VIEW ATTACHMENT ROD moving forward. BACK VIEW #8 x 2" Fh 1!/4" 1!/2" 1#/4" END VIEW SIDEWOODSCREW You can create the cutouts with a jig saw. Drill a hole just inside the 4#/4 SIDE VIEW layout lines to provide a starting point for the jig saw. TOP VIEW TOP (CROSS SECTION) Cut as close to the waste side of 2 the line as you can. This will reduce BACK STEP 1: XXXX XXXXXXXXXXXXXXX the amount of time it takes to sand away blade marks and clean up FIRST: XXXXXXX B F XXXXXXXXXXX the edges. D SIDE EXPLODED well. VIEW For starters, a. 2 a. c. PATTERN b. PATTERN NOTE: XXXXXXX XXXXXXXXXXX "INCH MARKS" “QUOTE MARKS” 3 (4!/2" x 25#/4") #8 x 3" Fh WOODSCREW #8 x 1" Fh WOODSCREW WoodsmithPlans.com #8 x 1!/2" Fh NOTE: ALL PARTS, EXCEPT RODS, ARE #/4" PLYWOOD SN10936 ©2012 August Home Publishing Co. All Rights Reserved. G H AA BB C C D D E E F F GG H H I I J J K K L L MM N N O O P P QQ R R I J SS T T UU VAV BWW X X Y Y Z Z K CLL A AA B BB C C C DD DD E E E F F F M N C GGG HHH I I I J J J K K K L L L O P E FIGURE FP P P Q QQ R R R MMM Final Size. With the cutouts com-NNN OOO Q R E the SS AA BB Hshape H I TI T T U UU HV V V WWW X X X6%/16 C Dlay GG S D Eout F F final plete, youCcan S T ZZZ YQ Y YR aR N N again, Q J Jthe O O P PI used K Kblank. L L MM I CLJ on Here 6!/4" X Y and U V SSsaw T T to UUmake W Xcuts V V Wthe Y Z Zthen RAD. K L jig PART NAME EEE F F F BB C C C D DD A AA B everything M N sanded smooth. W X VIEW LLL K EXPLODED J J J KisK complete, I I layer GNow GG HHH O P that I one OVERALL DIMENSIONS: Y Z VIEW R R R x 24!/2" x 24!/2") P Q QQ MMM NNN OOO P PTOP Q R you can use it as a template to(24!/2" shape 4#/4" PART NAME S SS T T T U UU V V V WWW X X X RAD. 4!/2 the other one so they’re identical. I CALLOUT S T PART NAME w/LETTER YYY Z Z Z CL (first time used) glued the two pieces together makTOP VIEW U V 3 ing sure to align the square end and W X long edges. Simply WASTE EXPLODED VIEWrough cut the OVERALL DIMENSIONS: Y Z bottom layer then trim it flush using (24!/2" x 24!/2" x 24!/2") a hand-held router and a pattern bit. PART NAME PART w/LETTER TheNAME final step to complete the baseCALLOUT (first time used) END VIEW TOP VIEW is to attach the casters to the bottom with screws (Figure 1a, page 3). PATTERN "INCH MARKS" “QUOTE MARKS” FIGURE 4 PATTERN HOSE HOLDER H #8 x 1" Fh WOODSCREW I HOLDER END #8 x 1!/2" Fh WOODSCREW (9" x 9") #8 x 2" Fh WOODSCREW A B 1!/4" 1!/2" 1#/4" #8 C x 1"D Fh WOODSCREW #8 x 1!/2" Fh WOODSCREW E F GG H H I I P QQ R R Y ZZ E FFF K LLL Q RRR W XXX #8 x 1!/2" Fh WOODSCREW G H #8 xI 2"JFh WOODSCREW a. K L M N O P Q R S THOSE 2!/2 HOLDER 1!/4" 1!/2" 1#/4" 7 !/2" RAD. b. HOLDER END BACK HOSE HOLDER 4 U V W X Y Z 9 SIDE VIEW PART NAME SIDE VIEW COVER HINGE TOP 3!/4" RAD. 4#/4 3" UTILITY HINGE W/SCREWS G Located between the two (CROSS cutoutsSECTION) in the base is the column. As ISTEP men- 1: XXXX END VIEW XXXXXXXXXXXXXXX tioned before, it provides stability to the cyclone and has racks for vacuum shop vacuum accessories. Just keep FIRST: XXXXXXX SIDE VIEW XXXXXXXXXXXin mind that the holes aren’t the attachments and the hose. TOP VIEW is made up of a NOTE: The column pair ofXXXXXXX same size, as shown in Figure 2a. XXXXXXXXXXX (CROSS SECTION) sides. These are connected by a top The lower holes accept a length of STEP XXXX and shelf1:(Figure 2, page 3). Both the dowel that supports the hose attach"INCH MARKS" XXXXXXXXXXXXXXX “QUOTE top and shelf have a cutout on oneMARKS” ments (Figure 2b). FIRST: XXXXXXX the hose that connects edge to accept Back. The next piece to make is XXXXXXXXXXX the cyclone to the shop vacuum. the back of the column. It’s rounded NOTE: XXXXXXX Accessory Rack. These pieces on the top to soften the corners. XXXXXXXXXXX also have a pair of holes to hold the There’s a slot cut in it to allow the 2!/2 a. #/4" RAD. COVER (9!/4" x 14") SIDE VIEW Accessory Column TOP VIEW 9 2!/4 3 3!/2"-DIA. HOLE connecting hose to pass through, as in Figure 2. You can make this slot the same way that you made the cutouts in the base. Cover. On the front of the column I added a hinged cover. It’s rounded to match the shape of the base, as you can see in Figure 3. The cyclone fits through a large hole in the cover to keep it stable in use. When you need to empty the bucket, remove the top hose and flip the lid clear. The cover also has a curved slot that serves as a handle. Vacuum Hose Holder. The final component to make for the cart is the hose holder that mounts on the back side of the column, as illustrated in Figure 4. The holder consists of six layers of plywood. Here again, I shaped one layer and used it as a template to create the other layers one at a time. The vacuum hose is held in place by an end piece. The end piece is attached to the hose holder with screws (Figure 4a). The hose rack is screwed to the column through the back, as shown in Figure 4b. With the cart complete, you can set the vacuum and cyclone in place and thread the connecting hose through the column. Now you’re ready to hook it up to your power tools and start collecting dust and chips. CALLOUT 4 VIEW TOP WoodsmithPlans.com SN10936 ©2012 August Home Publishing Co. All Rights Reserved. MAIL ORDER SOURCES Woodsmith Store 800-444-7527 Rockler 800-279-4441 rockler.com Project Sources Having a dust collection system in the shop can be really helpful. I found the Dust Deputy Kit (AXD000004) on Oneida Air Systems’ website. You’ll also need 3" locking swivel casters (38865) for the vacuum caddy. These can be found at Rockler. Oneida Air Systems 800-732-4065 oneida-air.com 5 WoodsmithPlans.com SN10936 ©2012 August Home Publishing Co. All Rights Reserved. 2 WoodsmithPlans.com SN08216 ©2012 August Home Publishing Co. All Rights Reserved.