super-charge your shop vacuum

Super-charge your
Shop vacuum
© 2012 August Home Publishing Co.
best-built jigs
& fixtures
supercharge
Your
Shop
Vacuum
A low-cost
cyclone kit and this
simple cart turn a
shop vacuum
into a top-notch
dust collector.
A shop vacuum comes in handy to collect dust and chips
from power tools and for all-around shop cleanup. But it
doesn’t take long for the filter inside the canister to clog
with dust, which reduces its effectiveness.
To prevent this from happening, Oneida Air Systems
designed its Dust Deputy kit shown above. It features
a small, plastic cyclone separator to direct most of the
1
WoodsmithPlans.com
SN10936
dust and chips into a five-gallon bucket. The kit shown
in the photo on page 2 includes a gasket with hardware
and an extra bucket to attach the cyclone directly to the
side of the vacuum canister. As the bucket fills with
chips though, things can get unbalanced. So I designed
the roll-around cart shown above to create a stable,
compact dust collecting center.
©2012 August Home Publishing Co. All Rights Reserved.
Exploded View
Details
OVERALL DIMENSIONS:
351⁄2"D x 17"W x 413⁄4"H
rack corrals hose when
not needed
vacuum attachments
slip over dowels
in rack
hose connects
shop vacuum
to top of cyclone
collector hose
fits into side
of cyclone
accessory rack
holds commonly
used shop vacuum
attachments
Hinged cover
holds cyclone in
place yet flips up
to allow you
to empty bucket
slot in back
accommodates
2!/2" hose
connecting
shop vacuum
and cyclone
cut-out handle makes it
easy to move the collector
anywhere in the shop
recessed
platform keeps
shop vacuum
stable and secure
Funnel-shaped cyclone
separates dust and chips
from airstream and
into collector bucket
collection bucket
rests in recess
in base of cart
large casters
easily roll over
power cords
and debris
Materials & Hardware
{ Oneida Cyclone Kit. The Dust
Deputy kit includes the cyclone,
two buckets, mounting hardware,
gasket, and connector hose.
2
A
B
C
D
E
F
G
WoodsmithPlans.com
Bottom and Rim (2)
Sides (2)
Top (1)
Shelf (1)
Back (1)
Attachment Rods (2)
Cover (1)
SN10936
17 x 351/2 - 3/4 Ply.
x 25 3/4 - 3/4 Ply.
41/2 x 14 - 3/4 Ply.
41/2 x 121/2 - 3/4 Ply.
14 x 36 - 3/4 Ply.
1 x 1 - 61/2
1
9 /4 x 14 - 3/4 Ply.
41/2
H Hose Holder (1)
9 x 4 - 41⁄2 Ply.
I Holder End (1)
9 x 9 - 3/4 Ply.
• (4) 3" Swivel Casters w/ Screws
• (28) #8 x 11⁄2" Fh Woodscrews
• (7) #8 x 3" Fh Woodscrews
• (1 pr.) 3" Utility Hinges w/ Screws
• (1) Dust Deputy Cyclone Kit
©2012 August Home Publishing Co. All Rights Reserved.
B
C D
roll-around
E F
G H
AA BB C C D D E E F F GG H H I I
J J K K L L MM N N O O P P QQ R R
I J
SS T T UU V V WW X X Y Y Z Z
K L
A AA B BB C C C D DD E E E F F F
M N
GGG HHH I I I J J J K K K L L L
O P
R this simple
Q QQ R Rof
P P Ppurpose
OOOmain
MMM NNNThe
Q R
is to
platform
X
V WWW Xa Xsingle
V Vprovide
U UU
S SS T T Tcart
T
Z
Z
Z
for
both
a
shop
vacuum
and Sthe
YYY
CL
Dust Deputy system. But you’ll Ufind
V
Cart
3
1
14
RIM
A
FIGURE
10!/2"-DIA.
HOLE
6!/4
2" RAD.
3
3" RAD.
CL
10#/4
there are a few other features as
W X
6!/4" RAD.
a flip-up cover
OVERALL DIMENSIONS:
Y Z
3" LOCKING
adds
stability to the tall, slender
(24!/2" x 24!/2"
x 24!/2")
PART NAME
SWIVEL
cyclone. Pulling on the hose
could
CASTER
A B
CALLOUT
PART NAME w/LETTER
cause
(first time
used)the cyclone to tip over withC DA
TOP VIEW
out this extra support.
EBOTTOM
F
SIDE VIEW
NOTE: ALL
Another feature is the center col(17" x 35!/2")
PARTS ARE
G H
AA one
HH I I
C C Dthere’s
BB side,
D E E aFrack
F GGfor
RIM
#/4" PLYWOOD
umn. On
P QQ R R
M N N O O Pused
K LL M
I J
storingJ Ja Kcouple
commonly
X Y Yon
SS T T UU
Z Z And dueKto Lits straightforward joinV V WW XThen
shop vacuum
accessories.
C D DD E E E F F F
C
C
AA
B
A
BB
M Nbuild it and put it to use
the
other
side,
there’s
a
rack
that’s
ery, you can
END VIEW
GGG HHH I I I J J J K K K L L L
O P
designed to hold the vacuum hose.
in just a weekend.
#8 x %/8" Ph
MMM NNN O OO P P P Q QQ R R R
WOODSCREW
SIDE VIEW Additionally,
Q R
the
rounded
base
X
X
X
S SS T T T U UU V V V WWW
stable base
won’t Ycatch
or workS T
Z Zyour tools
Y Y Zon
CL
TOP VIEW
bench.
And
the
large,
3"
casters
I began Ubuilding
the cart from the
(CROSS SECTION)
V
aren’t likely to get caught on power base up since all the other parts are
Two-Layer Base. The base
STEP 1: XXXX
cords EXPLODED
or cracksAin Bthe VIEW
floor.
attachedWtoXit. The base is sized to actually consists of two different
XXXXXXXXXXXXXXX
OVERALL
D is made from hold theYcyclone,
Z
Finally,
the CDIMENSIONS:
cart
bucket, and vac- layers of plywood. The first layer
FIRST: XXXXXXX (24!/2" x 24!/2" x 24!/2")
PART NAME
E F
XXXXXXXXXXXordinary, inexpensive
plywood. uum,
as shown in Figure 1.
is solid. The second layer has a
CALLOUT
PART
NAME
w/LETTER
pair of cutouts.
E F F XXXXXXX
G Hused)
AA BB C C D D ENOTE:
GG H H I I (first time
A
FIGURE
XXXXXXXXXXX
2"-DIA.
TOP
VIEW
The cutout on one end captures
J J K K L L MM N N O O P P QQ R R
I J
TOP VIEW
D
the
five-gallon cyclone bucket. On
X YY ZZ
SS T T UU V V W"INCH
W X MARKS"
K L
E
2
D
DD
E
E
E
F
F
F
C
the
other end, the cutout creates a
C
A AA B BB C “QUOTE MARKS”
M N
BACK
K KHK L L L
HHHH HI I I I I J J J G
(14"
x
36")
E EGGG
F F GG
rim
to keep the shop vacuum from
FO P
FRONT VIEWR R R
2!/2
MM
N NMO
R R P P P QI QQ
O PNPNNQQO OO
rolling
off the base.
F
J
2!/2
ATTACHMENT
Q R
#8 x 1!/2" Fh
ROD
X
X
X
WW
C
X YT YT TZ ZU UU V V V W
WWS XSS
To
create
the cutouts, I started
WOODSCREW
K L
(1" DIA.
x 6!/2")
L
END
VIEW
S T
Y EZEZ FZF F
YYE
D DD
M N
by
cutting
two
rectangular blanks
TOP
U
V
J J J K K K L L L TOP
at
the
table
saw
to match the width
O P
SIDE VIEW
2" DIA.
3!/2"
P P P Q QQ R R R
2!/2
3!/2"
and
length
shown
in Figure 1.
Q R
W X
5
DIA.
DIA.
CL
V WWW X X X VIEW
V VEXPLODED
TOP
VIEW
B
I
set
one
of
the
blanks
aside for
OVERALL DIMENSIONS:
CL
Y Z
(CROSS
C SECTION)
(24!/2" x 24!/2" x 24!/2") S T
the
time
being
and
marked
the
TOP
PART NAME
F U V
5#/8
(4!/2"
x 14")
TTACHMENT
STEP
1:
XXXX
CALLOUT
location
and
size
of
the
cutouts
SHELF
PART NAME w/LETTER
XXXXXXXXXXXXXXX
W X
1#/4
on the other blank. The cutout
TOP VIEW
EW (first time used)D
FIRST:
XXXXXXX
IONS:
Z
for the shop vacuum is sized to
Y
XXXXXXXXXXX
!/2")
D
12!/2
PART#8
NAME
accommodate most models, but
x 1" Fh
SHELF
NOTE: XXXXXXX
WOODSCREW (4!/2"XXXXXXXXXXX
CALLOUT
x
12!/2")
it’s a good idea to check the overall
CL
TER
B
#8
x
1!/2"
Fh
“footprint” of your vacuum before
TOPWOODSCREW
VIEW
ATTACHMENT
ROD
moving forward.
BACK
VIEW
#8 x 2" Fh
1!/4" 1!/2" 1#/4"
END VIEW SIDEWOODSCREW
You can create the cutouts with a
jig
saw. Drill a hole just inside the
4#/4
SIDE VIEW
layout lines to provide a starting
point for the jig saw.
TOP VIEW TOP
(CROSS SECTION)
Cut as close to the waste side of
2
the
line as you can. This will reduce
BACK
STEP 1: XXXX
XXXXXXXXXXXXXXX
the amount of time it takes to sand
away blade marks and clean up
FIRST: XXXXXXX
B
F
XXXXXXXXXXX
the edges.
D
SIDE
EXPLODED
well. VIEW
For starters,
a.
2
a.
c.
PATTERN
b.
PATTERN
NOTE: XXXXXXX
XXXXXXXXXXX
"INCH MARKS"
“QUOTE MARKS”
3
(4!/2" x 25#/4")
#8 x 3" Fh
WOODSCREW
#8 x 1" Fh
WOODSCREW
WoodsmithPlans.com
#8 x 1!/2" Fh
NOTE: ALL PARTS, EXCEPT
RODS, ARE #/4" PLYWOOD
SN10936
©2012 August Home Publishing Co. All Rights Reserved.
G H
AA BB C C D D E E F F GG H H I I
J J K K L L MM N N O O P P QQ R R
I J
SS T T UU VAV BWW X X Y Y Z Z
K CLL
A AA B BB C C C DD DD E E E F F F
M N
C
GGG HHH I I I J J J K K K L L L
O P
E FIGURE
FP P P Q QQ R R R
MMM
Final Size. With the cutouts
com-NNN OOO
Q R
E the
SS
AA BB
Hshape
H I TI T T U UU HV V V WWW X X X6%/16
C Dlay
GG S
D Eout
F F final
plete,
youCcan
S T
ZZZ
YQ
Y YR aR
N N again,
Q
J Jthe
O O P PI used
K Kblank.
L L MM
I CLJ
on
Here
6!/4"
X Y and
U V
SSsaw
T T to
UUmake
W Xcuts
V V Wthe
Y Z Zthen
RAD.
K L
jig
PART NAME
EEE F F F
BB C C C D DD
A AA B everything
M N
sanded
smooth.
W X
VIEW
LLL
K EXPLODED
J J J KisK complete,
I I layer
GNow
GG HHH
O P
that I one
OVERALL
DIMENSIONS:
Y Z
VIEW
R R R x 24!/2" x 24!/2")
P Q QQ
MMM NNN OOO P PTOP
Q R
you can use it as a template to(24!/2"
shape
4#/4" PART NAME
S SS T T T U UU V V V WWW X X X
RAD.
4!/2
the other
one so they’re identical.
I
CALLOUT
S T
PART NAME
w/LETTER
YYY Z Z Z
CL
(first time used)
glued the two pieces
together makTOP VIEW
U V
3
ing sure to align the square end and
W X
long
edges. Simply
WASTE
EXPLODED
VIEWrough cut the
OVERALL
DIMENSIONS:
Y Z
bottom
layer
then trim it flush using
(24!/2" x 24!/2" x 24!/2")
a hand-held router and a pattern bit. PART NAME
PART
w/LETTER
TheNAME
final step
to complete the baseCALLOUT
(first time used)
END VIEW
TOP VIEW
is to attach the casters to the bottom
with screws (Figure 1a, page 3).
PATTERN
"INCH MARKS"
“QUOTE
MARKS”
FIGURE
4
PATTERN
HOSE
HOLDER
H
#8 x 1" Fh
WOODSCREW
I
HOLDER
END
#8 x 1!/2" Fh
WOODSCREW
(9" x 9")
#8 x 2" Fh
WOODSCREW
A B
1!/4"
1!/2"
1#/4"
#8 C
x 1"D
Fh
WOODSCREW
#8 x 1!/2" Fh
WOODSCREW
E F
GG H H I I
P QQ R R
Y ZZ
E FFF
K LLL
Q RRR
W XXX
#8 x 1!/2" Fh
WOODSCREW
G H
#8 xI 2"JFh
WOODSCREW
a.
K L
M N
O P
Q R
S THOSE
2!/2
HOLDER
1!/4"
1!/2"
1#/4"
7 !/2" RAD.
b.
HOLDER END
BACK
HOSE HOLDER
4
U V
W X
Y Z
9
SIDE VIEW
PART NAME
SIDE VIEW
COVER
HINGE
TOP
3!/4"
RAD.
4#/4
3" UTILITY HINGE
W/SCREWS
G
Located between the two (CROSS
cutoutsSECTION)
in the base is the column. As ISTEP
men- 1: XXXX
END VIEW
XXXXXXXXXXXXXXX
tioned before, it provides stability
to
the
cyclone
and
has
racks
for
vacuum
shop vacuum accessories. Just keep
FIRST: XXXXXXX
SIDE VIEW
XXXXXXXXXXXin mind that the holes aren’t the
attachments and the hose.
TOP
VIEW is made up of a NOTE:
The column
pair ofXXXXXXX
same size, as shown in Figure 2a.
XXXXXXXXXXX
(CROSS SECTION)
sides. These are connected by a top The lower holes accept a length of
STEP
XXXX
and
shelf1:(Figure
2, page 3). Both
the
dowel that supports the hose attach"INCH
MARKS"
XXXXXXXXXXXXXXX
“QUOTE
top and shelf have a cutout on
oneMARKS”
ments (Figure 2b).
FIRST:
XXXXXXX the hose that connects
edge
to
accept
Back. The next piece to make is
XXXXXXXXXXX
the cyclone to the shop vacuum.
the back of the column. It’s rounded
NOTE: XXXXXXX
Accessory Rack. These pieces on the top to soften the corners.
XXXXXXXXXXX
also have a pair of holes to hold the There’s a slot cut in it to allow the
2!/2
a.
#/4" RAD.
COVER
(9!/4" x 14")
SIDE VIEW
Accessory Column
TOP VIEW
9
2!/4
3
3!/2"-DIA.
HOLE
connecting hose to pass through, as
in Figure 2. You can make this slot
the same way that you made the
cutouts in the base.
Cover. On the front of the column
I added a hinged cover. It’s rounded
to match the shape of the base, as
you can see in Figure 3.
The cyclone fits through a large
hole in the cover to keep it stable in
use. When you need to empty the
bucket, remove the top hose and
flip the lid clear. The cover also has
a curved slot that serves as a handle.
Vacuum Hose Holder. The final
component to make for the cart is
the hose holder that mounts on the
back side of the column, as illustrated in Figure 4. The holder consists of six layers of plywood. Here
again, I shaped one layer and used
it as a template to create the other
layers one at a time.
The vacuum hose is held in place
by an end piece. The end piece is
attached to the hose holder with
screws (Figure 4a). The hose rack is
screwed to the column through the
back, as shown in Figure 4b.
With the cart complete, you can
set the vacuum and cyclone in
place and thread the connecting
hose through the column. Now
you’re ready to hook it up to your
power tools and start collecting
dust and chips.
CALLOUT
4 VIEW
TOP
WoodsmithPlans.com
SN10936
©2012 August Home Publishing Co. All Rights Reserved.
MAIL
ORDER
SOURCES
Woodsmith Store
800-444-7527
Rockler
800-279-4441
rockler.com
Project Sources
Having a dust collection system in the
shop can be really helpful. I found the
Dust Deputy Kit (AXD000004) on Oneida
Air Systems’ website.
You’ll also need 3" locking swivel casters (38865) for the vacuum caddy. These
can be found at Rockler.
Oneida Air Systems
800-732-4065
oneida-air.com
5
WoodsmithPlans.com
SN10936
©2012 August Home Publishing Co. All Rights Reserved.
2
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SN08216
©2012 August Home Publishing Co. All Rights Reserved.