Dust Collection for Head Porting HELP!

[cspeier]

Hello Guys. Looking for some help. I'm a cylinder head porter, all aluminum, and I'm building a new shop. In my old ways, I used a shop vac, mask, and any eye/body protection. In my new shop I have built a downdraft style porting bench. This was tested with a shop vac. It works perfect for the cartridge roll dust, nothing escapes into the air. The chips will fall into the bottom of the downdraft table. I was going to plumb into the dust collector line to take them away. Or, I can manually dump them into a bucket. Here are my questions, concerns. I was going to use a shop vac, but decided on a "green" HF dust collector. Since I'm only 15 ft to my collector, is sizing a issue, I'm plumbed in 2". Now the collector itself. What about the aluminum chips? Do you think a shop-vac with a Thien lid separator would collect the aluminum chips?  Would a HF collector, plumbed in 2" with a Thien lid system be better than a shop vac?  All the collector will run is my downdraft porting section, chip removal..

Questions I know! However, I want to be safe.

THANKS GUYS,
Chad

[phil (admin)]

I don't know the size of the aluminum dust you're dealing with.  When I cut aluminum it is with a carbide-tipped blade and the chips are pretty large (and heavy).  My separator lid has no problem catching 'em and keeping 'em.

In your setup, it would be better to replumb your downdraft box w/ 4" fittings.  That is because the 4" pipes will provide far less resistance to airflow than the 2" will (and the more air flowing, the more chips/dust you'll be collecting).

Tell me more about the size of the aluminum dust you're dealing with.  I do have some concern that, if you were using a respirator previously, the fines are finer than I am thinking.

[cspeier]

Just like what your doing with your carbide, and yes they are big and heavy.

When you say replumb w/4", your talking the entire set-up correct? 

The dust is mainly from the cartridge rolls, it's horrible!  And the aluminum dust is fine when finishing the port.  I'll be honest, it's a horrible the amount of "dust" that is made.  Here is what I have for the downdraft.  It does work well with a vac.  I could totally remake it in a bigger box in 4"..  I was also going to install "drains" in the floor to take away the chips that fall through the aluminum top I made.  I played around with a piece of peg board until I found a hole layout that worked.

What about if I totally eliminated the pipe and just put a 4" drain in the center?  Would that work through a hole layout in the top?  Or does it need to be simular to this to be effective?

[phil (admin)]

Given the way your 2" is immediately branched in half with the tee, I'd suggest building a separator lid with 4" in and out.  Then I'd run 4" from the HF collector to the cyclone lid, then 4" from the cyclone lid to the downdraft you've built, where it would neck down to the 2".  Then try it and see how it works.  If you want better airflow, then build a new downdraft with 4" pipes on the inside.

[cspeier]

THANKS!!!!!!!!

One last question.  Can a HF "green" collector be mounted on top of a can with no issues?  I see photos of the red type, but wasn't sure.  Thought I'd better ask.

Chad

[dbhost]

There are several HF "Green" DCs. The 97869 http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=97869, which is the standard 2HP 5 Micron bag unit that is the current popular one, the 31810 http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=31810 which is the little sidways job, and the 45378 http://www.harborfreightusa.com/usa/itemdisplay/displayItem.do?itemid=45378&CategoryName=&SubCategoryName= which is the old 30 micron 2HP machine.

Generally speaking, for metal work, you will want as much as possible of your shavings and fine dust BEFORE they get to your impeller, and the bearings for it. And unless you want to be breathing that dust, AND introducing that fine dust into your work, you will want at least 1 micron filtration.

So... from your downdraft table, your DC circuit should look like...

4" port on your dd table.
Short run of 4" flex hose to a Thien Cyclone lid, (4" ports as well, look elsewhere here for examples of 4" cyclone lids), you should be on a 20 - 30 gallon HEAVY galvanized trash can. Thin walled stuff will suck in and fail. Plastic will not work well either.
Short run of 4" flex hose from your cyclone to your DC input section.
Wynn or similar fine filter http://www.wynnenv.com/35A_series_cartridge_kit.htm.

If you weren't dealing with metal dust / shavings, I would say just put a Thien baffle rig in the inlet ring of the DC and use the plastic bags. But no dice...

[cspeier]

I have a 31810. 

Short run of 4" flex hose from your cyclone to your DC input section.

So your saying I could mount the DC to the Thien lid?  Like this photo.

[dbhost]

Exactly... I have no idea how fine filtration that DC offers, but I SERIOUSLY doubt it is all that effective on fines. You will want to upgrade the bag to a fine filtration bag or better yet, a canister. Not sure how to adapt that though...

I don't see much on their web site about it, but check with Wynn Environmental about a filter for that thing...

[cspeier]

OK, I've been busy, LOL..  I totally changed the table concept.  IT WORKS PERFECT!  It really works well.  I made a Thien lid, and mounted the DC on top.  I ordered a better bag.  I've only tested it with saw dust, but so far things look promising.  Thanks for your replies, I'll keep you posted..  I also have a photo of what it will look like done.  I added a hood also.. I need to support the DC also, I have a make shift stand.

[bennybmn]

Nice setup! Whats the little upside down PVC "T" on the impellor?