Chris' new dust collector

[SpeedyDad]

If you look at my machine thread (Chris' Momus), you'll see that I started out with a crossflow style dust collection system. Air came in through strategically placed holes and exited via a 4" dust collection outlet. Since I work a lot with carbon fiber, it was important to get rid of the dust. The dust collector got most of the carbon dust out but it still pooled in some areas where airflow was not as good like up on the gantry and side rails. The exhaust on the router also blew a lot of dust out of the collection airflow. I spent a lot of time cleaning it to keep the rails free and running relatively smooth. I decided it was time to remove the dust and debris as it was cut so I looked around at various commercial options and designed this using ideas from these.

Here's what I came up with.
Pic 1: Shows the two plates right after they had been cut out. The main plate attaches directly to the router with 2 set screws. On the Ridgid 2400, the exhaust comes out of the bottom. The skirt plate had a small opening just big enough for the collet to fit through and a channel around that to direct the exhaust away from the work and up in to the dust collector hose. Without the skirt on, you can feel a lot of exhaust coming out of the bottom of the router. With the skirt plate in place, you feel almost none. You can also see the channel for the skirt. The two plates are held together when in use by rare earth magnets so the skirt is easily removable for tool changes. The magnets fit in the small round recesses.
Pic 2: Shows the dust skirt installed. I used conveyor strip brush from McMaster-Carr. It sits in the groove in the skirt plate.
Pic 3: Hose flange installed on the top plate. I cut down a reducer adapter I had and sealed and screwed it to the top of the plate.
Pic 4: The system is installed. The hose is 2" self-retracting so that as the machine moves around, it doesn't have to fight the hose. If this were an open machine, it wouldn't have been a problem, but the enclosure makes for difficult hose routing. It just wants to get in the way. I ended up settling on this arrangement. The hose enters the side of the top cover and then is clamped to the sidewall. It has to be routed forward like this to stay out of the way of the gantry. I've tested it several times now and it all works well like this. Why the hole in the side and not the back? I thought it would work out like that but the hose kept wanting to get behind the gantry thus blocking it. The dust you see in the pic is left over from when I cut the exit hole in the top.

So far, testing has shown an almost 100% success. I've done several cuts of carbon fiber parts and the rails have no carbon dust on them. I'm using 2" bristles which work well when cutting directly on the spoil board. I often use jigs for the shock towers I cut and they sit up a little higher. I also sometimes use longer milling bits. As a result, I'm going to cut another skirt plate and get some 3" bristle conveyor brushes and make another so I have options.

[OCNC]

That looks great. I particularly like the use of the magnets for ease in removing the brush. Thanks for posting the details and pics.

Chris

[HelicopterJohn]

Hi Chris,

Nice system you came up with.

I built one for my Shopbot. I have a vertical piece of Plexiglas with a slot in it that allows me to move the upper plate up and down. I made the spacers from 3/4 inch plexiglas so that I can add or subtract spacers as needed. I also purchased three different length brushes 1.3, 2, and 3 inch. With this system I am able to make almost any kind of adjustment necessary. Also, my actual brush in only 4 inches in diameter which has the advantage of a small suction area which has it advantages (less suction loss) when you are close to the edge of your table. Just thought I would share.

Included a few pictures for your amusement.

John

[SpeedyDad]

Thanks Chris

John, that looks pretty cool too.

[aarggh]

Great designs guys!

I've made a similar one for my machine but have had problems with the brush, the only local supplier I could find that didn't require the sacrifice of my first born in payment, had brushes ($25/m) that turned out the bristles were a little too spaced apart, so I get very mediocre suction at the machining point, but it does pick up the rest on other passes. I'm toying with a double ring to maybe improve it.

Do you know of a supplier that sells and ships these at a reasonable price? There is one on ebay that had them for about $15 each but $30-$40 shipping!

cheers,
Ian

[SpeedyDad]

Well, I've run quite a few carbon fiber parts lately and I'm amazed at how much cleaner my machine is and how much better my parts are coming out. I didn't realize how much the tiny bits of carbon dust were throwing things off. My rails stay almost 100% devoid of the black dust and my edges are so much smoother now. I just got some 3" bristle brush to make another skirt for when I run longer end mills.

[HelicopterJohn]

Hi,

If you are cutting carbon fiber parts you should probably use a good respirator if you are not already doing so. I hear that is nasty stuff for your health.

John

[cwelkie]

Thanks for updating all of us with our new dust collection system Chris. I've proven to myself what you learned earlier ... that the cross flow idea keeps the work area clear but isn't effective enough to keep the gantry clear. I did up an organizer for the bits and pieces I use with my rotary table in 3/4" ply and the gantry was a mess by the time I finished.

Could I trouble you to share the source and their description of the collapsible/retractable hose you used? Hopefully it didn't come from McMaster ... they don't ship to individuals in Canada (?!).

Thanks
Charlie

[SpeedyDad]

I got it through grizzly.com. Do a search for "Woodstock international hose". It wil show you several but you are looking for the ones that have a picture of them folding back on themselves

[cwelkie]

Thanks Chris! Sometimes I forget the most obvious ... Cheers
cw