My inspector explained that almost all small shop air cleaners and even fine cartridge filtered dust collectors and cyclones create a bad false sense of security because they use an under powered blower so have to use very open filters to let air flow which lets the finest unhealthy invisible dust pass right through.This web page provides general information on cyclone design, a detailed dimensioned drawing you can use to build your own cyclone from my plans, a spreadsheet that will let you design larger and smaller cyclones of this same design, and some of the details that led to developing this cyclone design.I believe most woodworkers can use these plans and building instructions to create not only the most affordable to install, but also the best fine dust collection system available today.
By 2004 thousands had already built their cyclones from these plans and building instructions. At that time Clear Vue Cyclones began making these cyclones for those who did not have the time or patience to build their own. ![]() Many have provided their suggestions, feedback, and questions to help improve these pages so most can build their cyclones without needing to contact me for additional help during the building process. Before you dive into building your own cyclone or blower, please be aware that if built improperly this equipment can cause property damage, hurt, and even kill, so please read the disclaimer make sure all you do is safe. Cyclone Separator Full Shop OfWith no sheet metal experience, most can build their cyclone in less than ten hours work, their blower in about six hours work, and their entire system with a full shop of ducting in under forty hours of work. If you dont want to take the time to build your own cyclone and blower, then you should seriously consider buying a Clear Vue Cyclone or a kit from my son. One of my most frequently emailed questions is why should I use your cyclone design when virtually every other small shop cyclone gets high magazine ratings and praise The simple answer is my cyclone design moves more air, uses less power, and provides over five times better fine dust separation which is what we need if we are going to use filters fine enough to protect our health. The following background gives a little history to share what drove my improved design. Unlike most, I not only grew up in woodworking, my background is in biomedical engineering, so I had a healthy respect for fine dust. I could do any large projects at either our family cabinet shop or university wood shop where I taught engineering. Both large shops had excellent professionally installed dust collection. I only did small projects at home in my garage with cleanup handled by a dust collector and shop vacuum. When I made fine dust at home, I did exactly what I still recommend to others who do not have really good dust collection systems. Before I make fine dust I put on my professionally fitted 3M NIOSH approved dual cartridge half face respirator mask, open my main shop door a few inches and turn on a strong fan that blows out the back door. Cyclone Separator Plus 2 HpI started a little better than most bringing home from the family shop two surplus 2 hp Cincinnati Fan dust collectors on roll around 55-gallon drums. I also had sunlight that came into my shop that let me see when there was airborne dust which was a poor mans particle meter. My two dust collectors did an excellent job collecting sawdust and chips, but the sunlight showed I had dusty air plus dust kept ruining my finishes overnight. Wanting to address this airborne dust I installed fine filter bags on both dust collectors. At first both worked far better because the finer filters had less resistance so improved airflow, but soon the filter pores clogged with dust that did not come out with normal cleaning. Seasoning improves filtering but also severely blocks airflow. It did save my finishes but sunlight showed it had to run for at least six hours before bringing the airborne dust levels down. I later learned when my shop was tested that a particle meter showed both my fine dust collector bag and my air cleaner filter freely passed the fine invisible unhealthiest dust.
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