Thien Baffle for Dust Collector




Introduction: Thien Baffle for Dust Collector

This is a Thien Baffle quickly created with a 5 gallon bucket.

Step 1: Dust Collector

The dust collector before attaching the baffle.

Step 2: Bucket

Cut a section out of a 5 gallon bucket.

Step 3: Circles

Use the bucket section to draw circles on a piece of wood. You will need three sections. One circle will fit on the inside of the top of the bucket, one circle will fit on the inside of the bottom and one circle will fit on the outside of the bottom.

Step 4: Cut

Use a circle jig and router to cut the circles. A jigsaw would also work.

Step 5: Circles

The left circle will fit on the outside bottom of the bucket section. It has a groove cut to sit on top of another full 5 gallon bucket. The circle on the right will fit on the inside top of the bucket section.

Step 6: Outside Bottom

Attache the outside bottom piece with screws and silicon.

Step 7: Hose

Cut a section of PVC pipe and round it to fit snugly against the side of the bucket section.

Step 8: Bucket Hole

Cut a hole in the bucket to match up with the PVC piece.

Step 9: Support

Cut a wood piece to support the PVC piece. Attach the PVC to the wood and the wood to the bucket section.

Step 10: File

File the inside of the bucket section so that it is flush with the inside of the PVC piece. Use silicon to create a seal between the PVC and bucket section.

Step 11: Inside Top

Cut a hole in the top of the inside top circle. Cut a piece to sit over the hole that will anchor dust collection tubing and glue in place.

Step 12: PVC

On the underside of the inside top circle use silicone to secure a PVC tube that will extend into the bucket section.

Step 13: Secure

Screw and silicone the inside top circle into the top of the bucket section.

Step 14: Inside Bottom

Divide the inside bottom circle circle into thirds. Cut an inch out from the side of two thirds of the circle. Screw the circle into the inside bottom of the bucket section.

Step 15: Base

Create a rolling wooden base to accommodate the collection system.

Step 16: Bag

Attach the bag and filter to the base.

Step 17: Support Arm

Create a support arm to hold the motor.

Step 18: Motor

Attach the motor to the support arm and attach to the bag and filter section.

Step 19: Dust Bucket

Run window sealer around the top of the dust collection bucket. Use a bit of glue or epoxy to secure in place.

Step 20: Baffle

Attach the baffle to the motor with tubing.

Step 21: Collect Dust

Lift the baffle and place the collection bucket underneath. The weight of the baffle and the pressure from the compressed tubing creates a seal on the bucket.



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    18 Discussions


    Question 3 months ago

    Hi, I have the problem, that a lot of fine dust escapes my standard dust collector which looks pretty much like yours. Probably it goes through the filter bag. So I am looking for another solution. Cyclone technology looks interesting to me.

    Could you tell me, how efficient you judge your solution? What about the fine dust? How much of the dust ends up in the bucket, how much makes it into the plastic bag?

    1 more answer

    Ill be honest I don't get a lot of heavy use out of the dust collector lately, but almost all dust ends up in my cyclone bucket, minus the finest particles that end up in the bag. I don't have a lot of fine particles escaping my system, but I also replaced my bag with a 1 micron substitute.

    These systems always run by applying a vacuum. Can anyone tell me if the reverse is applicable?
    Can you run the powered exhaust from a DeWalt 735 thickness planer into this system? If so, where you connect the exhaust and outlet??

    1 more answer

    Somewhere else in the www (youtube, I believe) I found a do-it-yourself cyclone attached to a planer exactly as you want to do it. Now extra vacuum necessary.

    What you do not say is what is the position of the thiem baffle in relationship to the inlet?


    1 year ago

    That is a really nice build on the filter, however, by rotating the motor/ impeller, you have or will shortly destroy your motor. Motors designed to be run in horizontal have no thrust bearings and when run in the vertical mode will shortly fail due to the rotor sliding down and striking the housing possibly also damaging your impeller. The motor in the HF collector is not designed to run in the position you have now mounted it. I have one of them myself and have made extensive mods to the system. Sorry to throw water on an otherwise great mod.

    1 reply

    This is good information. With the number of HF motors you see people mod to run in the vertical I wonder how many are having issues. I think I'll run in this position as an experiment and see how long before I notice trouble. I can always swap out the bearings at some point as an additional instructable. Thanks for the insight.

    That's a neat solution.

    I like it.

    Might just well plagiarise it!


    1 year ago

    What type of bag, filter, and motor? Where do you source them?

    1 reply

    Harbor Freight 2HP dust collector.

    This is a nice build! I personally like to use a cyclone (you can get them on ebay for about $20) which is essentially the same thing. But I can totally understand your situation with the larger hoses, thus the need for larger openings. I am using 2" hoses so the smaller orifices on the cheap cyclones works well for me!

    you really do not show the completed piece to determine what goes where. It appears that the intake is under the baffle, but I have always seen it where it must come in at the right place above the cutout of the baffle..

    2 replies

    thanks for this..

    This is a very thorough build. What are the advantages of a thien baffle?

    2 replies

    The Thien Baffle allows for easier emptying of the dust collected and also keeps the filter clean. When the filter becomes impregnated with dust it can reduce the efficiency of the dust collector.