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Build a Sander/Vacuum Box Dust Collector (for your girlfriend)

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Here is a very quick and easy table top dust collector that I put together for my poorest girlfriend as she was preparing to sand a bunch of resin cast picture frames. I was hoping to contain most of the nasty resin dust PLUS I had some old metal register metal that needed a project, so she got this box. The lucky thing!

First things first: please be safe and careful when using any tools. I nearly put a misfired crown staple into my thumb on this project because I was rushing - believe me, it slows the whole project down when you're trying to pry chunks of metal out of your digits, so take your time and be safe!

The tools I used:
  1. Table saw
  2. Mitre saw
  3. Panel saw
  4. Crown stapler
  5. Drill press
Materials:
  1. 3/4" plywood
  2. 1"x4" pine
  3. wood glue
  4. heat register sheet metal (this has a proper name but I'm not sure what that is)
  5. double-sided carpet tape
  6. black duct tape

 
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Step 1: Cut the wood!

The end of my shop vac hose happened to measure 1 3/4"; luckily I had a hole saw blade exactly that size. I drilled out the hole off to the left side because I figured this box would be sitting on Tina's work bench and the hose would be getting in the way more if it was in the middle.

The framework of the box was really simple glue and crown stapling the 1x4s together; next I added four strips of 3/4" plywood. I tried to make these strips flush to the top so that later I can lay the register metal across it.
Zeebert1 year ago
Some ideas...

The shop vac isn't designed to move a lot of air, the area you're trying to vacuum is humongous compared to the volume it vacuums. That's why you have no suction.

Suggestions:
Cut the plywood bottom off the box.
Go to Menards.
Buy approx 20" box fan & furnace filter which fits your box.
Cut a slit in the box to fit the filter edgewise.
Attach fan to bottom of box facing down so it sucks debris through the filter.
Add legs to make the filter box freestanding...

Just my two pence. If you don't like it, I'll give you a full refund.
damianzuch (author)  Zeebert1 year ago
Yeah, I dug around this website AFTER I made mine and found this: http://www.instructables.com/id/Fine-particulate-collector-on-the-cheap-I-Made-th/
I wish I had seen it earlier! Great idea though!
joelhunn1 year ago
Great idea and documentation, thanks! Plus, you've got a tracksaw, and I am sooo jealous.
damianzuch (author)  joelhunn1 year ago
Yeah, my girlfriend bought me that as a birthday gift one year, thus totally making her pretty much the coolest thing ever. It's such an amazing tool. I know Makita and DeWalt have similar systems but I love the precision of Festool. I built a wooden case for my tracks because if they get dinged it's near impossible to get them perfect again.
Hey, I can make you EVEN MORE jealous - check out this awesome new toy that she gave me this year - http://www.makita.ca/index2.php?event=tool&id=138&catid=57. Yeah, I know. Super amaze balls. I can make a brand new piece of 2x8 stock look like old weathered barn board in about ten minutes. Man, tools are great things!
Bill WW1 year ago
Very nice project that shoud help many of us keep our shop clean. Well described.

Larger (stadard) Shop Vacs have 2 1/2" hose; these units should move plenty of air for your design. But you have to work withwhat you have!
richms1 year ago
I am so making one of these!
What a great build, well explained and well documented! Thanks.
Kiteman1 year ago
Great idea!
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