ShopNotes #55 (Vol. 10) by Dust Collection Upgrade

Author:Dust Collection Upgrade
Format: epub

circle of the desired diameter (20" in my case) . Then use a jig saw (or band saw) to cut the base to rough shape. To cut it to final size (and to form the lip on the base) , I used a simple jig. Circle- Cutting Jig - This jig makes it easy to rout a circle using a hand-held router and a straight bit. The router is mounted to one end of apiece of hardboard (Figure 2). At the opposite end, a pivot pin lets you swing the router in an arc, cutting a perfect circle. (I used a nail as a pivot pin.) There are three separate holes (pivot points) for the nail (Figures 2 and 2a) . This allows you to rout three different-size circles — one to trim the base to size, and the other two to rout a rabbet that forms the lip. Trim Base -The final size of the base is determined by the location of the outermost hole. To find the centerpoint of this hole, you need to know file radius of the base (10" in my case). Then drill a hole that same distance from the inside edge of the router bit Note: You’ll also need to drill a centered hole in the base to hold the nail, To trim the base to size, start by setting the jig in place and installing the pivot pin. Then lift up on the router. A plywood box, a Plexiglas top, and a plastic trash can. A low-tech solution for building a high-performance chip separator. One look in the “window” of this chip separator says it all. A blizzard of dust and chips swirl into one side, and fine dust particles exit the other. No, this disappearing act isn’t magic. It’s a simple matter of letting the chips fall where they may. In this case, that means into a trash can. The secret is a T-shaped baffle that deflects incoming air and chips (Figure 1). This slows down the fastmoving air, causing heavy chips to settle in the trash can. With the big chips removed, only the fine dust particles are drawn into the dust collector. Trash Can - Just a note about the trash can. Be sure it’s made of rigid plastic (not soft vinyl). Otherwise, the vacuum created by the dust collector can make it collapse inward. (I used a 32-gallon Rubbermaid trash can.) Base - In use, the plastic lid of the trash can is removed, and its replaced with a plywood disk that serves as the base (A) of the chip separator (Figure 1). Besides enclosing the trash can, the base acts as a mounting surface for the baffle and a box that s added later. The base starts out as a square blank thafis 1W larger than the inside diameter of the trash can. This provides enough material to create a lip that rests on the trash can (Figure la) . After laying out the centerpoint of the blank, the next step is to draw a 18 ShopNotes No.

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