In this Instructable I will instruct you on how to take a street cone and turn it into an awesome cyclone to use with your shop vac.
THINGS YOU WILL NEED::
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a 5 gallon bucket with a good lid
one 8 foot 2x4 pine
3 feet of 2inch pvc
2 pieces of plywood around 10 inches square
40 3/4 inch screws
6 1 drywall screws
16 2 inch drywall screws
a 10 nch round piece of plexiglass
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Step 1: Cutting the Plywood Circles
The first thing is to cut 2 10 inch plywood circles using a bandsaw or jigsaw ,or scroll saw after the 2 circles are cut you will need to cut the center out to a 4 1/2 inch hole with the saw table angled to 10 deg.
In this step you will want to cut a 4 1/4 inch hole in the bucket lid to match the hole in the plywood and after this step you will sandwich the bucket lid between the plywood and drill a few screws to keep them together.
Then you can test fit the lid over the cone, it should fit it nice and tight around 5 inches from the top of the cone.
Step 2: Cutting the 2x4 and Ripping It to 2x2s
Noiw you will want to cut the 2x4 down to 24 inches and then using a table saw rip the 2x4s in to 2x2s
You will need 8 2x2s
Step 3: Getting the Angle
Now that you have the boards cut that support the cone you will want to place the cone on the bucket upside down on the bucket to measure the angle.
Using a angle finder to find the angle of the side of the cone mine is 10 deg your cone might vary
next you will measure the height of the board , mine is at 19 inches from long point to short point again yours may vary.
Step 4: Cutting Support Boards
In this step you will want to cut the angles on the supports
set your chopsaw to 10 deg
cutoff the end of your board
and then measure over 19 inches and mark your angle then cut on the line
also you will want to cut a chamfer on the cone side inner edge to accomidate the curve in the cone
Step 5: Attaching the Supports
in this step you will attach the supports to the cone
set one support block in place and screw a 2 inch screw thru the plywood into the support and then do this for 7 of them leaving one of the coner ones out for later
after those are screwed in turn the cone over and mount it to the bucket
now screw a screw thru the foot of the cone into the support to mount the other side
Step 6: Cutting a Hole in the Side of the Cone
in this step you will be cutting a hole to fit 2 inch pvcin the side
i didnt have a hole saw so i used a baseball bat that i cut the end off and sharpened as a hole saw
so i pushed the bat and twisted it till it cut a clean hole
you can also use a sharp knife to cut the hole
you want the hole in the corner so that the pvc will go in at the angle to run the dust around the inside smooth
Step 7: Cutting the Pvc
in this step you will cut a piece of 2 inch pvc to 12 inches long
the next step is to push the pipe in the hole and mark on the inside where the cone touches the pipe and thats where you cut for the inlet shape
leave the tip for a spot to mount the pipe as in the pictures
Step 8: Making the Pipe Fit Your Shop Vac Hose
in this step you will need a propane torch or heat gun
you will want to heat the end of the pipe till its flexible enough to stretch over your shop vac hose if it dont go heat it up longer and spin it as it heats in the flame
but you dont want to burn it as much as i was low on propane
(disclaimer ) be careful not to burn your self I warned you
you can also make other fittings in this manor
Step 9: Cutting the Plexiglas Top
cutting the Plexiglas top
i used a piece of 1/4 inch plexi glass i had on hand
i made a wooden template to mach the hole in the cone
i hot glued the plexi to the template and using my pattern bit on my router table i carefully routed it out
after the outer dia matched the pattern i did the same to the 2 inch hole in the center for the pvc
Step 10: Making the Inlet Pipe Fit the Shop Vac Hose
this step is the same as the other step in this step you will need a propane torch or heat gun
you will want to heat the end of the pipe till its flexible enough to stretch over your shop vac hose if it dont go heat it up longer and spin it as it heats in the flame but you dont want to burn it as much as i was low on propane (disclaimer ) be careful not to burn your self I warned you you can also make other fittings in this manor
Step 11: Cutting the Cone Tip and V Slots in Bucket Lid
ok now cut the cone flush with the wood
and also cut v slots in the bucket lit to be able to remove the cyclone easily
when time to empty the bucket
check out the pictures to see the v slots
Step 12: Installing the Top and Final Touches
ok in this last step u will install the pvc inlet on the cone with a screw going in to the side support
next you will cut the last wood support to fit under the pvc and screw it in to place like the other supports
next you will install the other pvc in the Plexiglas and place it on top of the cyclone
you can add silicone to all seems and pvc connections if needed
now your cyclone is complete hook it up to your shop vac and try it out
if you have any questions refer to the video or leave a comment and ill be happy to help you thanks so much for checking out my insructable
1 Person Made This Project!
nunol made it!