Dust Cyclone Separator (Shop Vac / Dust Collector) From a CD Spindle Cake Box and Toy Cone. Build Your Own Bucket Shopvac With Built in Cyclonic Separation!

You can build a fairly efficient cyclonic dust separator from just a couple CD cases, a toy traffic cone, and some PVC pipe. This dust separator can be attached to a bucket and used with an existing shop-vac.

You can also use this CD case dust separator to build a whole shop-vac entirely from scratch that performs just as well, is compact as, and is cheaper than an off the shelf shop-vac. All you need is a couple CD spindle cases, a toy traffic cone, a bucket, some PVC pipe, and a vacuum cleaner motor.

A friend challenged me to build something out of a CD spindle case and the first thing that came to mind was a cyclonic vacuum cleaner. Strange but true. A few months later, this product emerged.

You can see some video of early prototypes that I made.

To complete the CD case cyclonic separator module you'll need:
1x 50disc CD spindle case 1x 100disc CD spindle case

1x plastic traffic cone (found it at a department store sports/toy section)

3ft of 1 1/4" thin walled PVC pipe

1x 1 1/4" PVC straight union

1x plastic bucket with lid (doesn't necessarily have to be round)

To complete a DIY shop-vac with incorporated CD case cyclonic separator module you'll need in addition:

1x vacuum cleaner motor (can source from any spare vacuum cleaner)

2x 1 1/4" PVC 90 deg elbow 1x 100disc CD spindle case with lid

4x 3" x 13" boards

4x caster wheels

1x toggle switch

1x power cable

Step 1: Source Materials

To complete the CD case cyclonic separator module you'll need:

1x 50disc CD spindle case

1x 100disc CD spindle case

1x plastic traffic cone (found it at a department store sports/toy section)

3ft of 1 1/4" thin walled PVC pipe

1x 1 1/4" PVC straight union

1x plastic bucket with lid (doesn't necessarily have to be round)

To complete a DIY shop-vac with incorporated CD case cyclonic separator module you'll need in addition:

1x vacuum cleaner motor (can source from any spare vacuum cleaner)

2x 1 1/4" PVC 90 deg elbow

1x 100disc CD spindle case with lid

4x 3" x 13" boards

4x caster wheels

1x toggle switch

1x power cable

Step 2: Build Cyclone Subassembly

Start with a 50 CD case spindle. Cut out the base of the spindle (the black portion) such that the PVC pipe can fit through it.
With an extra CD cut a hole in it the same size as the PVC pipe and make a cut to the center of the hole.
Wrap the CD around the pipe and hot glue it in place to act as a spiral ramp.
Cut an oval hole out the side wall (the clear cylinder) of the CD case so the inlet pipe can be inserted into the case
Cut off the base of the traffic cone such that it can fit on top of the CD case
Cut the top off the CD spindle case

Step 3: Assemble and Glue Up the Cyclone Subassembly

Insert PVC pipe into center of CD case and glue in place
Insert PVC pipe into side of CD case and glue in place
Insert the cut CD around the center PVC pipe to act as the spiral ramp and glue in place
Attach traffic cone to CD case and glue in place
cut hole in bottom of traffic cone that is same size as PVC pipe diameter
Cut top off of 100 CD case and cut hole in bottom of the spindle
Glue the 100 CD case to the cyclone assembly to reinforce the cyclone structure

Step 4: Assemble the Vacuum Module and Mount All Assemblies to Bucket Lid

Fit vacuum motor along with AC switch and wire into a 100 CD case.
Cut a hole in top and bottom of CD case to insert PVC Pipe to top and bottom and glue these in place.
Cut holes in bucket to mount Cyclone sub assembly and Vacuum Module
Connect with PVC pipe, the suction side of the vacuum module to the top pipe of the cyclone assembly
Route with PVC pipe, the exhaust side of the vacuum module to the outside of the bucket

Step 5: Make Wheel Base for Vacuum and Add Vacuum Hose

Using any type of wood make a square frame that is the same diameter as the base of the bucket
Drill holes on each four corners of the wooden base and insert castor wheels
Attach vacuum hose to the inlet of the cyclone module
Insert a bag into bucket to catch the falling dust then test vacuum for leaks and performance