J. Phil Thien's Projects

Here are some another sites that carry Woodworking dust collection supplies. I purchased all my 5" metal ducting and flex hose
from these companies. Fast delivery, good selection and price.

Winn Engineering:
http://wynnenv.com/products-page/woodworking_hose/

Kencraft
http://www.kencraftcompany.com/Dustindex.htm

Look at this post. There is a PDF file there with my part Dem.

http://www.jpthien.com/smf/index.php?topic=847.msg4896#msg4896

ron

Don, Wow A TopHat separator for a Shop-Vac., what a great design. I can see lots of duplication with this setup.
Good luck and success with your Thien-Vac.

Ron

My top hat is also made for the Delta 50-760. It sits directly underneath the input port of the factory provided stand. Here is a PDF file of the part dimensions showing the location of the slot. A picture of the completed unit is attached.

Phil, Check your PM's

Ron

Put a Wynn filter on the top and keep the plastic bag on the bottom, You can see this setup on a lot of HF DC on Phil's  site.

Go to Wynn's website and see how to do it.

http://www.wynnenv.com/35A_series_cartridge_kit.htm

Good plan.

Why fight Mother nature?

Here is a very simple way to see the SD level.

http://www.jpthien.com/smf/index.php?topic=684.msg3979#msg3979

Ron

If you look at my bottom panel (lower left), which is 1/2 inch thick, I cut a baffle slot that is about 1 inch larger that the slot in the Thien Baffle. This supports the 1/8 inch thick Thien Baffle and maintains the "Thin" baffle that Phil recommends.

Doug, Good idea using a SM strip to cover the gap. I think that will be ok.

If you put the out side dimension's ( your ID 5.06 + 2* your SM thickness) into the spread sheet you should be able to see what the difference in the short/long tic marks would be.   

I looked at my transition and all the bend markings are on the inside.

1) Make a tight fit to the inside of the can. You should be able to pick up the can & TH using the TH only.
2) ok
3) If your only going to use it with your "ShopVac" just make the inlet/outlet the same size as the SV.
I built my first Thien Baffle, using Phil's original design, on a Ridge SV and have used it with all my tools for over 4 years. I used a 10 Gal can that sits on a small shelf on top of the Ridge SV. It is held in place with a bungee cord. It rolls around on the SV wheels. It works great See First picture.

4) Here is a drawing that shows the orientation of the baffle with respect to the input.  Second picture

5) see no. 4 drawing.

6) If your are referring to the length of the inlet, it doesn't matter.

7) 1 1/8 inch

Doug, To help straighten the small bends just place the round end  on a flat surface (edge of bench) with the form installed and tap the creases with a hammer. 
How much of a gap do you have on the round end?
From your drawing I see you were trying to fit the uncrimped end of 5" pipe inside of the round end. If you are off to far you could go with the crimped end which is about 4.97.
If you have a 4" to 5" or 5" to 6" round transition try and fit the 5" end over the round end of your transition and see if that closes the gap. If it does you could just leave it there.

I would build a Thien TopHat separator and set it on top of the barrel. There are many posts with as many solutions on this site and lots of HF DC solutions.

Here are a few posts for you to look at.

http://www.jpthien.com/smf/index.php?topic=90.msg466#msg466
http://www.jpthien.com/smf/index.php?topic=503.0
http://www.jpthien.com/smf/index.php?topic=262.msg1503#msg1503
http://www.jpthien.com/smf/index.php?topic=429.0
http://www.jpthien.com/smf/index.php?topic=563.msg3037#msg3037

Doug, Per your message, here are some pictures of the way I bend the Sheet Metal for the transition. The bends are only about 15 degrees so take it easy when you make a bend. The biggest issue, as you work around the transition it becomes rounded and hard to get it under your bench top I just forced it. I originally used to pieces ok angle, but the flat piece makes it easy to keep one end clamped when moving to the next bend line.

Picture 1 and 2: Angle and flat piece of metal (AL) clamped to edge of bench, with front edges aligned, as "Break". SM to be bent is placed between the two pieces with the bend line aligned to the front edge and clamped place.

Picture3: Make your bend

Remove clamp align your next bend line repeat until done. Try not to bent into the round and rectangular extensions any more than necessary. You can use the same setup to make the 90 degree bends for the rectangular corners.