How to Build a Shop Vacuum

If anyone runs or work in a shop where dust or other refuse particles are built up they may have seen a "shop vacuum" - it usually is hidden. These vacuums are normally found in garages, woodworking studios, plaster makers and hair salons. They make it easy to keep a place tidy that is prone to getting messy. This article will show you how to make your own shop vacuum.

Things You'll Need

• Electric screwdriver
• Wire cutter
• Wire stripper
• Light switch
• Switch plate
• Electrical wire
• Jigsaw
• Soldering gun
• Solder
• Hot glue gun
• Glue sticks
• Duct tape
• High-powered shop vac
• Wide mouth hose
• Wide mouth hose attachment with lip
• Screws
• Spool of metal wire
• Pliers
• Room
• Pencil
• Ruler or measuring tape
• Drill

Instructions

Preparing the Hideaway

1. Choose the room where you want your shop vacuum located. A storage room with an outlet is the best solution. Pick the wall that wold be best suited for the suction opening of the shop vacuum.

2. Measure the mouth of the wide mouthed hose attachment behind the lip and write them down. Use your measuring tape or ruler to make draw the measurements onto the wall, starting at the floor.

3. Drill a pilot hole into one of the lines then use the jigsaw to cut out the area. Insert the wide mouthed hose attachment so that the opening is facing the inside of the shop. Check for fit and trim if needed.

4. Locate the place on the wall where you want your light switch and place the switch plate over it and trace the inside with the pencil. Drill a pilot hole then use your jigsaw to cut it out.

5. Install the light switch through the hole you cut out in step 5 and screw it into place.

Modifying the Shop Vacuum

1. Locate the on and off switch to the vacuum and using your screwdriver remove the switch cover and then the switch assembly. You may need to access the plate from the inside of the machine. If so, remove the top section and locate the switch panel on the inner drum.

2. Look at the switch and determine which wire is the positive wire and which wire is the negative wire. Black is normally the negative wire but in any case it will either have a white line on the casing or the contact points on the switch will be labeled. Make a note of which wire is which.

3. Remove the wire leads from the switch but keeping the other end attached to the machine.

4. Unravel the electrical wire you purchased and separate the black and red wires. Using your wire strippers remove 1/4" of the wire casing.

5. Twist the ends of your wires to the switch wires in the vacuum matching negative to negative and positive to positive. Solder them together and add a drop of hot glue then wrap tightly in electrical tape.

Installation of Shop Vacuum

1. Place the wide mouthed hose attachment in the wall with the lip on the outside facing the shop.

2. Move the shop vacuum unit into the room where it will be kept placing it in the corner closest to the light switch and hose opening.

3. Attach the vacuum hose to the wide mouthed hose attachment and secure in place by wrapping the connection area with duct tape. Turn off the electric to the room you are installing the vacuum.

4. Run the switch wire along the floor and wall to the light switch. Cut off the excess wire and strip the ends. Install the negative wire to the negative contact and the positive wire to the positive contact and screw the contacts down in place tightly. Tape (or tack) the wires to the wall and floor.

5. Measure around the hose then snip off pieces of metal wire the same length plus two inches. Use the pliers to bend the ends of the wire into small loops then twist the ends around the main wire to secure the loop in place. You may solder it into place as well. Make several of these double ended looped wires as needed.

6. Pull the hose tight so that the mouth of the hose attachment is flush against the outside wall. Wrap the double ended looped wires around the hose and secure them into place by putting the looped ends onto the wall then hammering a nail inside the loop. Repeat as needed to keep the hose flush to the wall.

7. Screw on the light switch plate. Turn the power to the shop vacuum to the on position. Turn the light switch to the off position. Turn the power to the room back on.

8. Flip the light switch to the on position to turn the shop vacuum on. You may now sweep your debris to the wide mouthed hose attachment.

Tips & Warnings

• If no storage room is available you can easily build one out of 2 x 4 and drywall and run an extension cord into the room through a jig sawed hole.

• Always check your measurements twice before cutting.

• If the vacuum is on top of a wheeled base remove it and let it sit directly on the floor.

• Shop vacuums can be fairly loud. To dull the sound place the vacuum on top of a comforter and wrap the drum with it.

• When modifying your vacuum do not have it plugged in OR in the on position.

• When working with electrical wiring always have the power shut off.

• Working with power tools can be dangerous. Observe strict safety precautions.

• Always check and recheck the current flow of the wires before turning the machine on for the first time.