Dust Collection: Cyclone & Thien Baffle

About a year ago I started a dust collection project with a first stage based on a cyclone and a second stage with a Thien baffle. I got as far as the intro video (on the old camera) and that was about it. After dust buildup prooved to be a problem with the box-joint jig, I had another go.
The fail video referred to is • Video (it doesn't come up if you search, at least not for me).

[@T70781]

A $35 cyclone from EBAY or a Dust Deputy cyclone will capture 99% of the visible particles in a single stage. A properly designed Thien baffle will capture over 98%. If you are only capturing 60% in your first stage then there is a design problem or possibly a leak between the inlet and exit of the cyclone.

[@IrishChippy]

My thien baffle two bucket system is as close to 100% (more than 99.9%). Must have been beginners luck

[@andrewcluff3275]

If you're having near 100% you're only vacuuming thick coarse dust no fine powder like particles.

[@andrewcluff3275]

Cyclones only filter out heavy coarse dust they do not do anything for extremely fine particles. You can think your Cyclone is doing better because you're only vacuuming course material try a bag of flour and see how well your Cyclone filters.

[@FredYB67]

@@andrewcluff3275 thats not true, I have designed cyclones in the past and the level of separation is less than 1 micron. dysons cyclones manage a cut point of 1 micron (calculated and tested). a single large cyclone with shopvac airflow can easily get a cut point of less than 1 micron the largest particle a human can see is around 50 microns.

[@aramgreuter9631]

The vaccum attaches to the top, the dust enters from the side, it looks like the hoses are connected wrong...

[@crackerjack3359]

Ever heard of a jig saw?