J. Phil Thien's Projects

retired2 -  thanks for the link.  that's going to be a big help.

jdon- no worries.

now all i have to do is wait for the weather to warm up some so i can go build this thing.  i did not get heat for the garage, aka my shop, this christmas.

Thanks for the input retired2.  Do you have a link or some pictures of your build?  I'm looking around but can't find any.

Hi everyone, 
There is a lot of good information on here....maybe too much.  I have a HF 2hp dust collector.  I want to add a top hat separator to it so I have been reading and reading on the design.  I think I am over complicating it and in information paralysis.  I scored a free 15gal fiber drum that has a 16" diameter and that's I want to use.  I'm putting the drum and collector on a cart so I can move it around.  Space is at a premium - my shop is a one car garage that is currently sharing space with the snow blower, lawn equipment plus some other things.  I'm using 4" fittings.  I'll be running one machine at a time – 10" contractor table saw, 6" jointer, 12" planer, router table, saving for a 14" band saw.  I know you can go crazy building this but I'm trying to keep it simple and cheap as possible.  I'm a hobby shop and I make and sell pieces from time to time to help support my habit.
Here's my idea based off of what I have read and the guideline pdf I found:
The inlet will be a 4" rectangle and located close to the top cover.
The height of the separator (from the baffle to the top cover) will be 4 ½ -5".
The outlet will be 4" and will project into the separator so it is 2" from the baffle.  If I read it correctly the outlet pipe should stop above the baffle half the diameter of the outlet pipe. (Outlet pipe is 4", half of that is 2" so it should stop 2" up from the baffle)
The baffle will be made out of 1/4" or 1/8" hardboard - forget what I have on hand.
The top cover will most likely be made from plywood – 1/2" or 3/4" - forget what I have on hand.
The drop slot for the baffle will be 1 ½" wide with a chamfer and go around 240 degrees.
I see that people like to use poly carbonate for the walls...that hard to bend?  I was thinking of using sheet metal or formica.  To attach the wall to the baffle what's the best thing to do?  Just route a groove and bend it into place?  Any ideas or comments are greatly appreciated. 
Thanks in advance for any help and make it a great day,
Mike