Dust Collection - I can't breathe!!

[Erik]

Like most of you I have spent a lot of time thinking about installing better dust collection. I found Bill Pentz’s website a bit overwhelming at first, but by about my tenth reading I finally started to get what he was talking about. I had three big take aways from reading his work: first, you need to reliably deliver 1,000 cfm to most tools to capture the most dangerous dust and get it to the dust collector, 2) most tool ports are inadequate to handle that much air and so need to be upgraded and 3) you should monitor the dust continuously so that you are informed about the dust level in your shop.

Here is what I ultimately did when I added a third bay to my garage last year to create 375 sqft of dedicated shop space. I was fortunate that when we added the shop I could research and plan for dust collection so that it was not an add on like in my previous workspaces. (old wooden sheds and carports).

- I purchased the ClearVue CVMAX when it went on sale. The system delivers about 1,900 cfm when wide open and with my estimated static pressure, elevation in Colorado (6,800’) and 6” ductwork I know I am getting more than 1,000 cfm to the tools ports. The Pentz website has a nice spreadsheet to help you calculate the static head which can then be used when looking at the blower tables. My runs are very short, but I still calculated about 8” of static pressure and when I scaled that for elevation the static pressure approached 10”. That surprised me and is one of the reasons that I purchased the CVMAX.

- I upgraded the tool ports to 4” where possible and always run two lines to every tool. For example, I have the SharkGuard for my Mark V when in table saw mode with a 4” line and run another 4” line to the lower saw guard where it is squeezed down with a good coupler (Nordfab) that maximizes the air flow underneath the table. I also made all of the modifications to the lower saw guard that have appeared over the years in the Forum. Same story for the bandsaw (where it was easy to upgrade to a 4” port), jointer and belt sander.


- Again, on Bill Pentz’s advice, I purchased the Dylos DC1100 Pro particle counter so that I know exactly what the particle count is in the shop (the Pro model monitors 0.5 and 2.5 microns). I turn the monitor on when I am in the shop and if the particle count moves out of the “good” range I flip on the dust collector to clean the air. And, of course, I run the dust collector when I am using any tool.

It was not cheap to install a high-end dust collection and monitoring system. I have about $4,000 into the setup when you include the DC1100, the ductwork (I sprung for Nordfab metal because the system is modular and the air flow is better), new ports (used Rockler Dust Right system), hoses and Shark Guard. Nevertheless, it was the smartest “tool” that I have ever bought (the Jessem TS hold downs is a close second!). The most surprising thing to me is that after a long day in the shop the air is often cleaner than when I started. Dust doesn’t settle on everything and I don’t track dust into the house. There are still some things – like disc sanding – that I can’t get good dust collection on and so for those operations I roll the Mark V out into the driveway and work there. The steady winds in SW Colorado make short work of dispersing the fine dust from sanding.


-Erik

[DLB]

... (the Jessem TS hold downs is a close second!)... There are still some things – like disc sanding – that I can’t get good dust collection on and so for those operations I roll the Mark V out into the driveway and work there...
-Erik

Erik - Just to clarify, please. You mention the Jessem TS, which makes me think you are most likely using a SS 520. So on disc sanding, are you saying collection is inadequate even running the disc in the lower saw guard and through the table? Reason I'm asking is all perspective, pre-510 we had essentially no dust collection for disc sanding and went to vastly improved for 510/520/M7. So I guess I see it as pretty good compared to none. I think you are probably saying it is also pretty bad compared to good. (?) Just want to make sure that is what you mean.

- David

[Erik]

Hi David,

You are right: the dust collection for the disc sander on my 520 is much improved over what was possible, but in my view still not up to scratch. With the disc sander on my 520 I run a 4" hose with adapter to the lower guard (where I get most of the dust) and a 5" hose with a 12"x7" hood positioned on the table (where I get a lot of dust, but not enough). What I need is something like a SharkGuard above the table to gather up the dust like happens in the table saw mode.

As an aside, this is where having a particle counter comes in handy. No matter how I configure things, I can see the particle count rapidly creep up when I use the disc sander. It's simpler for me to roll the 520 outside and work there or switch to my home-made drum sander which has excellent dust collection (an enclosed housing with two 4" ports).

-Erik

[number3456]

I too run 2 - 4”, sometime add 2 1/2 inch depending on the tool. I have switched some of them over from 2 1/2 to 4”. The 4” on jointer made a world of difference.

I have not purchased a particle monitor but am considering getting one. Not sure which one as there are quite few available.

My 3M cartridge face mask is my go to when I sand as like others have said sanding is tough.

[WoodFrog]

I am sure the systems you guys are discussing are much higher end, but I just picked up a https://www.rockler.com/dust-right-dust-separator and am using it with a Craftsman ShopVac. I am really happy with the results and the price is great!

I also wear a 3M cartridge respirator whenever I am making sawdust. I don't have the best lungs so I keep it on most of the time I am in the shop.

WoodFrog

[number3456]

I was using a cheap dust filter then I switched to a 3M cartridge respirator and what a world of difference it made. I felt so much better at the end of the day after using the cartridge respirator.

[shoedo]

Realistically, I can't afford to spend 2.5 - 3k or more on a dust collection system but I am not willing to jeopardize my lung health for a system that only provides a minimum level of protection. I think the shop smith dust collector and a quality mask may provide suitable coverage. I wish others will chime in and provide suitable strategies for combating this common problem.

[RFGuy]

Realistically, I can't afford to spend 2.5 - 3k or more on a dust collection system but I am not willing to jeopardize my lung health for a system that only provides a minimum level of protection. I think the shop smith dust collector and a quality mask may provide suitable coverage. I wish others will chime in and provide suitable strategies for combating this common problem.

Check out the forum thread that I listed before. It is repeated below. In it, I describe how I am using a ShopVac™ with a ClearVue CV06 Mini cyclone with my Mark V. This setup cost me less than $200 and has been working better than my DC3300 so I retired it. It is not for everyone, but you can do a lot with a shop vacuum and a small cyclone (especially in a small shop size). Just invest in the HEPA filters for the vacuum. If this doesn't appeal to you, pick up a used DC3300. I see them often for $75 on craigslist, etc. I recommend buying the 42" filter hood (1µm filter) to add to it and you will likely have to take the DC3300 apart and make sure it is sealed well inside (sometimes it leaks sawdust). You can use the particle counter as a guide to see how well it is working with the 1µm filter.

https://www.shopsmith.com/ss_forum/begi ... 22666.html

Also, consider getting a dust particle counter so you can know what the dust level is in your shop. The cheapest one is on Amazon:

https://www.amazon.com/gp/product/B07DL ... UTF8&psc=1

P.S. The primary benefit of a large $3k dust collector is high airflow (CFM) to support duct work in your shop. If your shop is on the smaller side, a smaller dust collector or even a shop vacuum can be more than adequate with a short length of hose.

[RFGuy]

Thanks Ed. All very good points that you make. I too find the new Oneida Supercell to be intriguing. It is a great form factor for smaller shops, but I'd like to see how it holds up in the market a bit first. They use 3 smaller motors similar to a shop vacuum motor with plastic impellers. Of course, if these break, the replacement isn't too expensive (https://www.oneida-air.com/replacement- ... -motor-kit), but that is the only thing that gives me pause with their system. Still it looks very interesting.

Yes anything new could have some problems that have yet to surface and so far as I know they are the only one addressing the market at this time. If their sales are go I can see other companies following suit.

Much of the information on dust collection is not quite as clear as it should be. You have people wanting you to buy systems which I see is clearly overkill and not all that much designed for home shops.

This is the reason I have started on a trek towards Festool. I have a couple of "chop" saw that cut fine but even after a new cuts I'm covered in saw dust and so is everything around me. The Kapex is not perfect but is so so much better then the other saws at collecting dust it amazes me. I was out working and a neighbor stopped by with a couple of pieces of wood he need cut. So I did it for him on the kapex. After I did the cut I realize I had on the sweatshirt that while nice and warm is a saw dust magnet. Looked down and nothing, not a chip to be found. I would have done that with one of my other saws and I would have spent 20 minutes cleaning the jacket up.

Ed

Here's a video of Oneida's Supercell DC being installed and reviewed. Not a lot of new details in the video, but still good to see a video on it that didn't come from the manufacturer. It looks like it definitely sucks (pun intended). Interesting comment on the video was someone else had installed it and liked it, but they did say that it generates A LOT of heat in their woodshop. Don't know if they are running it continuously and if that explains the heat or not...

[youtube]https://www.youtube.com/watch?v=magB6okni6w[/youtube]

[ShoptimusPrime]

I use a shop vac bucket lid vacuum and a dust deputy. Works great! I also use blue tape to seal up the gap behind the lower saw guard, the guard on the table, and two wide strips on the underside of the zero clearance insert. This cuts down the dust to almost nothing. Also waxing and buffing the inside of the lower guard helps a lot as well.