J. Phil Thien's Projects

I guess I was not clear. Your baffle is not circular since a 90 degrees section touches the bucket side and the remaining 240 degrees is spaced 1 1/8" from the side. Why can't the baffle be circular ( radius 1" smaller than bucket) not touching the bucket at any point?

I am only using the Shop Notes as a design idea, but adding my own ideas. When I am done it will be the same physical size, but with full wings and  adjustable fences. Check this one out.

http://local.americanwoodworker.com/Mobile_Miter_Saw_Stand_Sun_City_Center_FL-r1332837-Sun_City_Center_FL.html

Do you have pictures of your 5 gal design?

I have found some of them, including the test with chalk dust, but I have not found a discussion concerning the shape of the baffle. In particular, for a bucket or trash can design why can't the baffle simply be circular?

I wish to make a 5 gal bucket ds for my miter saw.  Elsewhere in this forum, such separators have been built, but I did not see any pictures. Maybe I just missed them. At present I am building a CMS cabinet similar to the following and wish to place the vacuum and separator inside.

http://mikefromwinton.com/mtrsaw.html

None the less, I will try my version of the DS using a HD bucket and some 1 1/2" PVC plumbing parts. First I will try a design without the baffle and then if I can find the tempered hardboard I will add the baffle. I will add pictures as I progress for anyone who might be interested.

I have a small shop for which I have a blog of my projects.

http://workshopprojects.blogspot.com/

My real interest is in the design of a CNC router. See

http://cncrouterbuild.blogspot.com/

Questions for Phil about shape of baffle plate in the bucket design?

It seems to be a circle with a 240 degree cut out on the circumference of about an inch. Did you try a disk that was simply a 1" smaller radius? Is the 90 degree section against the wall of the bucket necessary? I realize that in some designs that 90 degree section holds the plate in place, but for the bucket design that is not necessary since standoffs are holding it in place.

Did you try different widths of the cut out? 1/2", 3/4" etc.

Did you test your unit with different particle sizes?  Sanding particles? MDF dust? Wall board dust? I expect that Dyson spent much time playing with his vortex tube to make it work with a broad range of particle sizes.

I think your baffle is a clever idea. It would be interesting to play with its perimeters.