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Topics - chaosdsm

#1
I am a hobbyist woodworker & have been using a Shop-Vac for dust collection.  Added a Dust Right separator a little while back, but unfortunately, my Shop-Vac died the weekend before 4th of July. 

Fortunately, I found a Grizzly 1.5hp wall mount DC with HEPA canister filter on sale & purchased for a little over $720 shipped to my door!!! 



But, I don't like having the impeller exposed to incoming dust, dirt, wood chips, etc...   I also don't like the idea of stepping down to the 2.5" inlet/outlet on the Dust Right. 

So I've decided to build my own Thien Baffle separator.  I went to Rural King & bought a cleaned & refurbished 55gal drum, then found a cap style lid on Amazon. 



My plan is to use 6" fittings to tie into the drum lid, then put a 4" side collection into the drum.




Obviously a work in progress, I'll use Silicone sealant, galvanized repair mesh, and bolts to secure the 4" boot to the drum & seal up any leaks around it.

But I got to thinking.... would I be better off putting the baffle just below the inlet as everyone else does, or would it possibly work better if I installed the baffle just at the top of the inlet? 

Seems like if I were to put it on top of the inlet, it would physically block some of the finer dust particles from entering the 6" duct.   

Has anyone tried anything like this?  If so what were the results???

I'm also thinking of cutting off the tongue off of the baffle, then re-attaching it with a piano hinge.  Then all I have to do to empty the drum is remove the top, flip up the tongue of the baffle and empty the drum.  Any thoughts on this?