How to make a sound baffle for loud shop vacuums

Picture of How to make a sound baffle for loud shop vacuums
Have a loud shop vac that you use for a stationary purpose, like sucking up chips off of the shopbot or dust collection for your table saw? This Instructable will show you how to create a sound baffle to minimize some of the noise. By the way, I made it at Techshop!
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Step 1: Gather materials, preferably scrap.

Picture of Gather materials, preferably scrap.
This project is meant to be functional rather than beautiful and is done with no budget, so the first order of business was to collect suitable scrap materials. I found 2 pieces of 2" scrap foam, 54" by 30", out by our container, and a few pieces of scrap ply board near the plastics station. (Actually, the availability of properly sized scrap foam was the impetus for this project.)

If you don't happen to have access to a giant pile of scrap or if you want to go out and buy new materials, you can follow this Instructable but make a much nicer looking final product. 

2 sheets of 2" foam, 54" by 30", or whatever suits your purpose.   
4 pieces of 1/4" or 1/8" ply scrap (owsyp)
About 16' of 1.5" by 0.5" strips of board
Staple Gun
Drill with driver bit
Wood Screws 
(wood glue for the corner supports if you're not lazy like I was)

Step 2: Staple the foam to the boards

Picture of Staple the foam to the boards
Lay a piece of your foam on a table. If your boards aren't already sized, cut them down so that the tall side of the boards is the same length as the width of the foam. Place the boards on top of the foam so that each board aligns itself along 3 edges of the foam. If there is a gap between your boards, put it in the center. This is what your staple job will look like when it's finished. Flip the whole thing over so that the foam is on top of the boards for easier stapling and fine-tune your alignment. Now staple the edges of the foam to the boards along the 3 outer edges. Repeat this step for both sets of foam and boards. 
tonyvelour (author)  Wroger-Wroger2 years ago
good call. I'll do this to ours today!