How to Make a Bottom Feed Dust Collector

Dust in a wood shop can cause skin irritation, respiratory problems and even nasal cancer. The greatest danger comes from the tiny particles, some as small a hundredth the diameter of a human hair, dispersed from tools like sanders. Dust control systems take most of these particles away at their source. A key component is a bottom feed dust collector, also known as a down-draft dust collector.

Things You'll Need

• 1/4-inch pegboard
• 3/4-inch stock
• 1/8-inch hardboard
• 1/2-inch stock
• Table saw
• Wood glue
• Drill with bore bit and countersink bit

Instructions

1. Cut the 1/4-inch pegboard to the size you want for the top of your bottom feed collector box. A good size is 15 to 20 inches square. Cut a piece of the 1/8-inch hardboard to the same size. Use a drill with a countersink bit on each hole on one side of the pegboard. This side will be the top.

2. Cut your 3/4-inch stock to the size you need for your box. You will be using a 3/8-inch rabbet, so if your pegboard is 20 inches on one side, that side of the box will be 20 3/4 inches (20 inches + 3/4 inch on each end - 3/8 inch on each end for the rabbets). Cut the 3/8-inch rabbets 1/4 inch deep along the inside top edge of each side.

3. Cut a 1/8-inch groove 1/4 inch up from the bottom edge along the inside of each side piece. Miter the ends of each side to 45 degrees. Drill a hole in the center of one side to attach the vacuum hose. The size of the hole will depend on the size of your box, the size of your vacuum hose and the availability and size of adapters. Holes sized 1 1/2 to 2 1/2 inches are common.

4. Cut two cleats, 3/4 inches wide and long enough to fit onto an interior side of the box, from your 1/2-inch stock. Attach them with brads to two of the side pieces, but not the one with the hole. Assemble all the sides of the box, except the side with the hole, with wood glue and brads. Add a bead of glue to the groove at the bottom and slide the hardboard in. Attach the side with the hole to complete the box.

5. Cut two pieces of hardboard to add as baffles to direct the dust toward the hole. They should run the length of the box; one edge of each should rest against the side of the box and the cleats on either side. The other edges of the baffles should meet at the bottom of the box along the center line. This should create a "V" pointing directly toward the hole. Secure the baffle with brads and glue.

6. Place the top of the box so it rests on the rabbets. Do not secure the top to the box. You will remove the top when you need to clean out the box. The top should fit snugly. Attach the vacuum hose to the hole.

Tips & Warnings

• Devices like down-feed dust collectors are part of a dust mitigation system. Such a systerm is not a substitute for personal protective gear. Always wear a dust mask or respirator when working in a wood shop.

References

• Controlling Dust in the Workshop; Rick Peters; 2000