Harbor Freight 2HP Dust Collector Modification Part 3/3

Modify a one-stage Harbor Freight 2HP dust collector to a two-stage with a Thien baffle. Key takeaways:
- You don't have to pick up the motor while you measure.
- You don't have to spend a lot of money.
- You don't have to rebuild the dolly.
I also post pictures of things I build on Instagram: / thesnekkershow .
This video is not sponsored, but I may earn a small commission if you use one of these links to make a purchase:
Rockler 4” x 2' stretch hose: amzn.to/3bDOXsH
Rockler 4” x 4' stretch hose: amzn.to/38VGuQ5
4” black corrugated snap coupler: amzn.to/3bR03uM
Rockler threaded disconnect fitting: amzn.to/3nW9mvu
4” hand-keyed hose clamps: amzn.to/38Vf6Bv
4” PCV coupler: amzn.to/3imTUaV

[@svar77]

I have watched pretty much all the videos related to Harbor freight dust collector modification, but your set of videos seems to be the best out there which utilizes the existing rolling base that comes with the set, in its most efficient form to house everything including the baffle. Nice work and thanks

[@TheSnekkerShow]

Thanks for the feedback

[@WJR1965]

Nice Job! You might consider adding a floor sweep to the bottom of your unit so that when your Rockler tubing gets disconnected from your power equipment and "docked" into that coupler, the suction airflow would get connected to the floor sweep (mounted to the bottom of your unit).

[@TheSnekkerShow]

Thanks, good idea.

[@pouncethecat8]

Best mobile cart / motor mount I've come across - thank you for posting.

[@TheSnekkerShow]

My pleasure

[@robgriffioen101]

I liked your single handed approach of over coming your motor mount. I also liked your idea of attaching the garbage can under the motor. My thought instead of the 4 bolts to attach the garbage can lid, would be to create a dadoed track on 3 sides of that square plywood piece, for it slide along. The opposite corresponding 3 dadoes would be on the piece on the bottom of the motor. The garbage can would then hang on and the suction would make the seal when it was turned on. A lot less time mounting it each time. Thanks for your ideas.

[@TheSnekkerShow]

Thanks. Good idea about using dadoes, although the weight of the full can might pull off the lid if not supported from underneath.

[@donf3739]

I can't believe how lame the original design of that HF system is. It has to suck everything through the blower to get to the bag, and a person would spend most of the day cleaning chips out of the intake screen. This is the right way to do it. Thanks for the ideas.

[@gingabuilda3803]

Thanks for the coupling suggestions and the design ideas! I really like the way this came out and will be doing a similar modification to mine.

[@TheSnekkerShow]

Good luck with the build. Thanks for commenting.

[@jefffoggymountainworkshop5021]

Nice instructions on a well built cart. Going to use some of your ideas on my HF mod. Thanks

[@TheSnekkerShow]

Thanks, good luck with the project.

[@clfields0524]

Nice setup. Copying most of your design for my setup in just a few days.

[@TheSnekkerShow]

Thanks, good luck with the project.

[@garymac121]

This is very nicely done. Thank you for sharing. I have decided too buy the HF DC And modify it and am gleaning ideas. One thing I'd like to ask is if it is necessary to still use the filter and bag if you are able to pass a hose outside instead?

[@TheSnekkerShow]

Thanks. The filter is not necessary in that case, but keep in mind that if you run the hose out of your shop you'll also blow out your air, and maybe cause the outside air to get sucked back in.

[@bigpapaporsche1]

Very nice ideas!

[@TheSnekkerShow]

Thank you.

[@daniboi79]

Very nice setup. Just got my HF dust collector and plan on building the same cart. Just have a few questions. How did you seal the OSB to the lid? What length is the Rockler hose and do you recommend it? Did you have to place sealant between the lid and the rim of the can; if so what did you use? I used the same trash can for a two-stage setup with my shop vac and the can collapses every time I turn it on. Hoping not to repeat that with this build (although I’ll have to buy a new can).

[@TheSnekkerShow]

Thanks, glad you liked it. I used Gorilla Glue Construction Adhesive to seal the OSB to the lid, but since I put sheet metal screws around the perimeter any kind of caulk or adhesive would work. The hose is Rocker item# 57111 in the 28' length, because it can reach any corner of my shop without moving the system. So far no complaints about the hose except the price. I didn't use any sealant between the lid and the can - Because of the taper in the lid it seals pretty well, and since that's in the intake end anyway the worst that could happen is it sucks a little extra dust out of the air into the filter.

[@joecox9958]

would you mind to give purchase links for your parts? say the rubber quick connector and sch20 coupler? your cyclone baffle looks different than Thien's, any details on it? My personal feel is that the opening is a bit complex, you might allow motor assembly on a vertical slide. thanks for your video.

[@TheSnekkerShow]

I added some links to the description. I should probably post a separate video on the baffle, but it should be pretty close to the Thien concept. I used the 4" steel fittings inside the baffle because I could angle the one on the inside downwards (slightly) to help the dust drop, but PVC or black dust-collection fittings would probably work just as well. I've seen several different variations of the Thien baffle online and I don't recall seeing one yet that just plain didn't work.

[@drodver]

How tall is your unit after your modifications? How stable is it? I'm a little worried that mounting the motor high on the cart might make it dangerous with small kids around.

[@TheSnekkerShow]

68" to the top of the filter. The motor is narrower than the base, which helps with stability. If someone wanted to tip it over they could, just like a chest of drawers or bookshelf.

[@TheFalconJetDriver]

Great Video thanks for sharing your talent, the coupling for the corrugated drain pipe did you find that at a big box store? If not do you have any suggestions for where one can be located. Also how did you secure the 4x4 post to the D.C. Plat form? Was a doubler plate used on the bottom of the sheet metal with screws in to the end grain of the post? How secure is it the post? Thanks Lane

[@TheSnekkerShow]

Glad you enjoyed it. I found the coupling at Home Depot, and I've also seen them at Lowes goo.gl/UEkWxW. The metal on the platform was thick enough that I just drilled some holes through it and put #10 x 3" screws directly into the post. How much force that can resist will depend on the screws and wood that you use. Mine was capable of standing vertically with the motor attached (I tested it), but if you build it horizontally the screws shouldn't ever have to do anything other than keep the posts from shifting side to side. They're more like legs on a table with this design.

[@jameswestii454]

What length did you end up cutting your 4x4's to?

[@TheSnekkerShow]

4'

[@martyjosephson4937]

what happened to the Wynn filter?

[@TheSnekkerShow]

Still got it, and it's still working fine.

[@mikedurkee7296]

What is the overall dimensions... the original HF dust collector is 22"x33" -- my space is quite limited. I know this is old and you are more than likely tired of talking dust collection :)

[@TheSnekkerShow]

Mine is around 22x48x70 inches. The 22" is not including the elbow sticking out from the trash can, which could be rotated to the side if necessary.