Cyclone Dust Separator (Shop Vac Hack)

I had been thinking over this design for a while now. I wanted to make a dust separator that didn't have a hose or pipe connecting it to the shop vac, and I wanted it to be a single unit to make it easy to move around and take up less space.
I watched a lot of other people's take on dust separators but the 2 that really helped me with this design were Cosmas Bauer and Matthias Wandel.
This was the simplest solution I could think of and the cheapest, buying only the bucket and using scrap plywood for the rest. I am very happy with how it turned out. It works great and its not overly bulky or fiddly with hoses or wooden frames going everywhere. And it just so happened that the base of the bin fits inside the wheels of my Ryobi shop vac!
My shop vac:
www.ryobi.co.nz...
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[@Fireballwilly1]

Dude! The way you cut that circle with the table saw is Genius!!

[@ThekiBoran]

Check out Peter Parfitt. He shows an easy way to cut circles with a router and scrap wood and maybe a nail. I use a finish nail.

[@agrafes6]

Ken Williams You read my mind. 👍🏻

[@JinWang]

I paused the video at 1:40 and wanted to comment exactly what you wrote.

[@oneeyedphotographer]

@@ThekiBoran I have a base for the job. The router (laminate trimmer) screws travel in recessed grooves. Loosen, adjust using digital caliper, tighten, cut circles. It can make quite small ones, 100 mm or so, and larger ones depending on the length of the base. I don't normally take the base off.

[@liugerard3201]

@@agrafes6 Same feeling!

[@mattyjames1548]

I've become a bit obsessed with dust collection lately. This is by far the best design. Wicked job

[@Ritalie]

Can you explain why a manufacturer doesn't make a shop vacuum with a cyclone technology on it? It would require them to simply add a single 90 degree fitting inside the tank so the air swirls inside the tank, but they intentionally point the fitting straight down to create maximum turbulence and shittiness. It makes no sense.

[@johnvodopija]

This is by far the best DIY dust collector I’ve seen. Combining the shop vac and dust collector bucket all in one unit is fantastic. This is now my next shop project (I am still dragging around a vac and separate dust bucket = hose tripping hazard). Thanks a lot for sharing. 👍😎🇦🇺

[@johnvodopija]

I just finished building one based on your design and wanted to say another thank you 🙏

[@thesesh5629]

I was literally watching other videos like why don’t they just use a bin and then after searching up bins to build my own this pops up 😂 what a world, well done mate !

[@rick6653]

Awesome video. I like to see people working in a basic shop and how they improvise with equipment they have. So much more interesting than watching some one with the latest and greatest equipment. It shows real woodworking skills.

[@TheOffcut]

Thanks Rick! Though I wouldn't mind having the latest and greatest haha :P

[@trakyboy5128]

So true... gotta love the use of the table saw and sled!!😋

[@mikeyv2014]

I watched many DIY separator videos, but this by far cought my eye. I like the fact that it's one piece and don't have to drag the shop vac and can around. So went and made one, let me tell you the thing WORKS. What a great vid. Thank you for sharing.

[@TheOffcut]

Thanks! Thats so cool to hear. I'm glad it worked out well for you! Its definitely a huge help in my shop!

[@markkoons7488]

Your circular work on the table saw and use of a hole saw to sand a bit off the inside if a hole are new to me and seem like well, I hesitate to say genius, but very clever and effective. At 8:55 you struck a truly universal note.Thumbs up and thank you!

[@TheFeyling]

That was some clever woodworking. Love the table saw hacks, love the thought process, and the dust collection seems superb! Kudos.

[@knarftrakiul3881]

Some people are just blessed to have their own workshop full of tools

[@Mike--K]

Great video! There is nothing wrong with derivative work and it was great to see you use the tools and material on hand to make a functional addition to your shop. The cherry on top was the bin fitting in the Ryobi base. Well done, sir!

[@TheOffcut]

Thank you!! Yes, that was pure luck that the bin fitted on the base haha

[@prashanpremaratneAU]

I watched more than a dozen so far and this one is the best engineering design that prevents any dust coming on to the filter

[@TheOffcut]

Thanks! I did the same before making my one. Spent a long time thinking about it

[@nathanmorrow6981]

I like how he used the wheels from the shop vac on the bottom of the bin to make it mobile. Top notch thinking.

[@mmgross144]

With the only potential issue being that the vac is top-heavy, that's BRILLIANT! I look forward to more videos.

[@poly_hexamethyl]

9:08 I love your technique for making a circular disc using a table saw! Ingenious!

[@fakiirification]

I saw a similar technique on another video once, and made myself a dedicated tablesaw circle cutter jig. has a sliding pin for easily adjusting the radius, and holes every half inch for pre measured sizes. So handy. Just wish there was a better way for cutting the inside diameter. have a similar jig for my router table, but it burns through bits, few cuts and its time to sharpen again.

[@worldofzap]

Think I have seen Diresta do something similar. His time lapses are hypnotic.

[@jerrywatson2737]

fakiirification ;

[@jerrywatson2737]

fakiirification TI’m 7The 5xx 9

[@tobygathergood4990]

Yup...this technique was taught in my school wood shop some 53 years ago....and every other school wood shop that I know of back in the day.

[@cognitor900]

Enjoyed the neat clean build but loved the sigh at the end AND the shop vac dolly fitted the bin base!!! Best small footprint build on the net. Tried to imagine wandering around hardware store with an opened box holding the shop vac and trying to size the shop vac base to the bins....without getting thrown out the store!!! And then I read in the comments that you just jagged it.... !!!! Been watching yr tool and skill progression and your just going ahead by leaps and bounds. Cmon tool manufacturers.....give this guy a break...he's out there encouraging and inspiring us to buy stuff (to cut in half because the manufacturers still can't hear after 20 yrs of cyclone development that we want a small cyclonic woodshop vac for under $60....then we can buy 3-5 of them to use everywhere throughout the shop) so that we can buy more tools for the tool merry-go-round .... Thanks for going to the effort too of filming, editing and overlaying a soundtrack. Loved the incongruity of 70's nightclub lounge lizard musak with getting the job done in the workshop.... Now I'd better get one with building something (anything!) so I can get closer to having my own "sigh moment"!!

[@TheOffcut]

Haha thanks for the love! When I bought the bin I did have the idea of using the dolly from the vac to use for the bin and kept the size in mind but I didn't expect it to fit as well as it did.

[@tbip2001]

I have my shop vac permanently in one corner then an extension hose runs up the wall and across the ceiling to the center of the workshop. What's left is then long enough to reach all four corners of the workshop. Basically a central vac system . Great build man :)

[@slippinggnome]

Best design for the project I've seen on KZbin. Nice

[@moonolyth]

Excellent on the lip with the table saw! No fancy stuff... (THATS FANCY!!) I used a router to make a rebate. But liked that method! Get your self two grinders, cheap ones they last. One for a flap disk another with a cutoff wheel.. (Or one for both) you won't look back !!! A dust collector must filter 5 microns or better out a window. Many shops look clean as a whistle but the floating particles are what dead you, not a clean shop. I don't use a filter, it goes out the wall. Like your build!!!

[@SarenaBarrett]

Great idea! Blow it out the window so we can all breathe it!

[@apoc2500]

The ingenuity of using a table saw to cut a circle really got me! I always feel like the inlet is too close to the exhaust. With this it at least separates the two for better collection of those fine dust particles

[@Johan_Pentrose]

Holy Shit...when i grow up i hope i am half as good as you are doing this... this is simply beyond brilliant...there is no way i could make this...just brilliant! Loosing sleep now wishing i had one this nice an ingenious that i made myself....cant say enough so i will stop here👍

[@shaunl452]

I must have looked at 30 dust cart build videos over the last few days and I have to say that yours blows them all away ! If Dyson decided to get into the workshop buisness I'm pretty sure they'd steal your design to pimp their machines. I have a cheap Titan vac which is almost identical to your Ryobi and I'll be building one of these bad boys just as soon as the Coronavirus social distancing restrictions are lifted (if that ever happens ;) Many thanks.

[@TheOffcut]

Thanks very much! I looked at a lot of builds too before coming up with this design. Good luck with your build! and stay safe!

[@shaunl452]

@@TheOffcut Update: I finally got round to building my own using your design. The bin I used turned out to be too flimsy and collapsed in on itself as soon as I turned it on (ain't atmospheric pressure a bitch ;) so I had to give it an internal plywood ribcage which fixed the problem. What really surprised me is that the suction through the hose is definately more powerful than it was before the build. Don't understand how, perhaps because the vacuum developed is of a much greater volume ? I'm also finding that the height added to the controls and hose attachment make it much more ergonomical to pull around my workshop, which means I'm much more likely to use it more often to keep the dust and sawdust levels down. So thanks again and keep designing :)

[@TheOffcut]

@@shaunl452 Thats great to hear! Glad you were able to fix the bin collapsing problem. My bin must be pretty sturdy as I only get that problem if I accidentally block the hose. I agree that with the higher height making it easier to turn off and on so I am more likely to use it. Hope it serves you well!

[@jwdickinson643]

I don’t see this as a hack....this was obviously very well thought out, planned and meticulously executed. Good job!

[@TheOffcut]

Thanks very much :)

[@powder749]

Soooooooo...I just subscribed to Matthias Wandel not long ago because I keep seeing his name pop up on other makers' videos. This video was in my suggestions as I was looking at DIY cyclone dust collectors. Imagine my surprise when I read your description and saw Matthias' name in there. This is an excellent design and will be my next project for sure. Oh yeah, your subscription counter is now +1 too. I'm a truck driver and don't have much time in my humble shop just yet, but I do have lots of time to watch KZbin videos, so your playlist is my next binge session. 😉

[@powder749]

Oh yeah, I created a new playlist titled "projects" for this one too.

[@TheOffcut]

Awesome! Thanks for the comment. And all the best with your projects!

[@joe-edward]

I may have watched this video a hundred times. I can't get enough of it. Great video!

[@TheOffcut]

Haha not sure why you would watch this 100 times but thanks!

[@joe-edward]

Honestly, it's the music and no commentary! I love that format! Plus that build video just also happens to show an awesome upgrade that Ryobi themselves should market. @@TheOffcut

[@fullonmopar]

Luv the smiley face in the bottom of the bin when first showing the dust collected.

[@nateb4543]

Some of the other shopvac dust separator set ups would take up half my shop. Well done!

[@UnicornMeat512]

The level of planning is so impressive. I can't stay focussed long enough for that. Nicely done.

[@jack0cat]

Very cool and looks great too much like the one that I built but my shop vac is on the bottom with the hose going from the vac to the dust collector then a pick up hose from the collector. A testament to “what ever works” very cleverly done 👍👍

[@NathanNostaw]

Great build. I love the sigh of relief when you finally cut through the vac drum.

[@jimnz17]

hey bro, i looked at so many of these. yesterday i chopped up my vac and bin just like yours. works perfectly.. 10/10 man.

[@TheOffcut]

Thats awesome to hear! glad it worked out!

[@Twoholesofman]

This video is a great example of knowledge is power. I watched you use a bunch of basic tools that most woodworkers have to make things that many people have designed "shortcut" tools for. Very cool video. Liked and subscribed.

[@TheOffcut]

Thank you very much!

[@haiyanqu698]

To me, this is by far the best all-in-one shop-vac with dust separator!! Thanks so much for sharing!!

[@Bernycoty]

Excellent travail ! bravo

[@Fight2BeFreeNeverGiveUp]

Table saw for cutting circular shapes, and the thought going into the cyclone bin, epic man. Best I've seen.

[@tommythompson6543]

You can also use it to make dowels... truthfully...I don't know the address right this moment, but I'll try to find it...

[@andrewwilds1878]

Dude, you are clearly thoughtful, planful, and precise...I commend you on this build! I love this video!

[@adamlott6681]

Brilliant. The table saw trick was genius. Looks like a lot less dust and faster setup than with a router.

[@TheOffcut]

Thanks! That was the reason I did it on the table saw :)

[@pumpkinheadghoul]

I've never seen so many ingenious ways to void so many tool warranties in one video. AWESOME build, my friend!

[@olddingodude]

Haha true but what he made is awesome. On my todo list

[@pumpkinheadghoul]

@@olddingodude SAME!

[@TeknixTrix]

Love the way it fits together without a hose between the top and bottom sections *serendipitous* to be sure . . . ;-)

[@blakeyokum1547]

Awesome! Loved your thought process. I especially liked the technique you employed on the cut off sled to turn your disc's. Going to use that idea on future projects. 👍

[@Utubecstalker]

I was just thinking of how to do this last week with my old craftsman. Was thinking, why make a separator when i have a perfectly good cylinder from the old can. You have saved me a lot of planning. Thanks.

[@salleman112]

Good job and great video. I always enjoy watching what can be made by people working in a basic shop. I am fortunate to have more/better equipment, but I don't think I could do better.

[@TheOffcut]

Thanks Scott :D

[@dennishorne1220]

That is a great design !!! I've been looking around KZbin at everyones designs but yours fits my needs perfectly. Terrific job !!

[@haroldland4620]

good fun mate ! just a safety tip ( from a 35 year woodworker)... use push sticks on the table saw, that pile of offcuts is trouble waiting to happen. My friend cut his thumb off last week going for waste on his table saw...

[@jimsjacob]

That was well done! Nice background music selection and I’m glad to see that I’m not the only one with a bit of clutter in the garage.

[@karlsangree]

Fantastic! Everything was top-notch from the concept to the design to the construction. Well done sir.

[@AMC-eq3jr]

Out of this world. Great sharing your work. Greetings from the USA.

[@joedance14]

Terrific work! Great design and great execution. I love it. I have been thinking of something like this for months, but somewhat smaller. Made one with a Buckethead wet/dry vac atop a two-bucket cyclone for the miter saw. It’s compact, but seems under powered. Currently going a different direction, with a small, second hand household vacuum accompanied by a relatively small cyclone, for overhead dust collection on the table saw (with a shopvac and its cyclone connected to the standard dust port). Again, great work. Keep it up!

[@nateb4543]

My first set up was hard to empty and underpowered. Since it fell apart in the move i want to do it right. I now have a 2nd shopvac and want to connect them for more power but not take up half my garage. Since only 1 will have the final filter, i may cut a bucket in half, stick inside itself for the smallest possible container for 2 vacs. Ive got a lot going on eith my plan, half his tools and a quarter of his ability. How did yours turn out?

[@joedance14]

@@nateb4543 Well, if the truth be told, I never really got there. A lot going on around here, remodeling, a wedding, a move, grandchildren, a hip replacement and much more. Although I really liked the integration of the shopvac & dust separator, in terms of appearance and size, I eventually came to understand that there is good reason for keeping them separate. The dust separator of the integrated unit captures mainly chips, and the shopvac filter captures mainly dust. However, a system with separate dust separator and shopvac adds another important layer - the filter bag in the shopvac helps to clean MORE dust from the air stream, so the main filter lasts longer, and the system captures more dust overall. Still rearranging my garage shop, wood storage, new tools, etc. to have space and functionality. It’s not a destination, it’s a process. Best wishes!

[@robertwinder2969]

Just completed my own using a "Shop-Vac" from Home Depot...works great. Thanks for the Video. by the way using a 2" pvc pipe will work with the standard shop vac hoses. Just got to modify the pipe. using a heat gun, NOT a torch heat till pipes becomes soft, then jam the wand into the pipe and rotate till it cools. WA-LA....a perfect fit for your hose. Again thanks.

[@TheOffcut]

Thanks for the tip! I might have to try that!

[@theatticwoodworker4594]

excellent idea and the table saw circle cutting was ingenious

[@geoffroberts4342]

That’s probably the best solution and execution I’ve seen for a shop vac dust separator. I really like it!👍😉

[@michaeljacobs9613]

*The* best shop vac cyclone combination i've seen on youtube!

[@arkansasmountainman]

Great to see you using all the safety gear you should. I think this is the best "safety" video ever! Keep using them, you only get one set of body parts that are original! Replacement parts don't always work and cost a WHOLE LOT!! Great video otherwise too. Loved the editing!

[@danhartman9087]

.....that sigh of relief at 8:55. So funny! Great project, great job! Very usable shop tool. Far less foot print than the vac/cyclone cart I made.

[@PTechMedia]

Dan Hartman I saw that as ' oh shit... now I need to file down the rough edges

[@dwied10]

Would have been worth it to spend $20 on a Harbor Freight angle grinder

[@slavakeizik]

,, Ччч,,,1

[@mattyjames1548]

I thought it was a frustrated sigh cause he realized that he had to cut another circle and didn't do it with the other one?

[@hiranga]

great footprint! great use of the wheels from the original vac too!

[@andymckenzie8031]

This is fantastic! I love the design, and I think I'm going to try to copy it with my shop vac. Thank you!

[@usedcarsokinawa]

Great idea. I have been thinking how to make mine take up less floor space, I think this is it!

[@JohnOSullivan_bray]

awesome build again. best home gamer dust extraction I've seen on KZbin

[@TheOffcut]

Thanks man!

[@daviddavis5689]

If that can is as tough as the Brute ;you'll have no problem. It really doesn't take much vacuum with a single use collection system like that. My 6hp Rigid is over kill for single use as dust collection. Good build.

[@futures.scalper.808]

I've always wondered why other makers do a 2 part vac and cyclone, nice job!

[@rippvanwinklestein2126]

Your circle.cutting game is off the charts

[@byejason]

From a few seconds in I was seeing little things that made me think you were in NZ, then I saw the Fortress screws and I knew it! Really great job, i'm tempted to copy it exactly.

[@TheOffcut]

Haha wow good eye! I don't even know where in the video you can see the fortress screw label haha. And thanks!

[@erikjansen4732]

Jason Bye, do it, you'll love it!

[@TimSavage-drummer]

I guessed either Australia or NZ from the tools (I have many of the same tools).

[@GH-sx6tk]

Dude! epic design. I can see a lot of people doing the same after watching this video! So awesome. Well done.

[@TheOffcut]

Thanks Glen!

[@benstrait333]

Yup, I'm absolutely copying this for my shop!

[@jamesautry7432]

With the popularity of this style of shop vac modifications, one would think the makers would catch on and start making them in this fashion

[@justaguy8347]

That is the coolest one I've seen! Thanks for the idea and the video, I'm going to do something just like that!

[@phbrinsden]

Really well done and unusual but clever use of the tools you have at hand.

[@paulkline515]

Beautiful, compact, efficient. I mean, if you are willing to cut the bottom off your shop-vac, then it is easy isn't it? LOL The quick show of relief after doing that is precious! I would probably cut the circles on my bandsaw and laminate the two sized pieces together. Great job and thanks for making this video!

[@capitaldd5840]

Great finished product. Everyone should have one of these - such a time saver and health saver. I need to make one as well....... Thanks for posting

[@mostlikelywedoitservices9743]

Nice build. Nice use of the table saw and sled.

[@Filelor]

I abs love shop work in fast forward.. esp sanding... the sound is supremely satisfying... lol nice work on the canister!

[@BlameItOnGreg]

Haven’t seen a baffle done like that before. Nice work!

[@woodworking_automation]

Very nice build, thank you for sharing. I built a similar one using the Ryobi 4.7 Gal Vac.

[@russellfay6771]

THAT IS GENIUS ! ! ! BRILLIANT ! ! ! Absolutely what I've been looking for! One-Stop Vac Shop! Can you make the plans available again? THANKS!

[@mapexlegend]

Bloody on ya for the effort with the old hacksaw. Good to see a little hard work n just making it happen!

[@critter469]

That’s a great idea and you are very clever. I’m going to make one of these for myself. Thank you for sharing.

[@Ritalie]

Go to 10:00 to see the finished product. Wow, such a good job on the accuracy and precision of all the cuts, and parts. I can't believe how much quality you put into this, it looks like it would take weeks to complete? It seems like every single part has razor tight accuracy, that had to have taken a really, really long time? Or maybe you had a lot of practice building these, because I feel like it would take me literally 3 weeks to build this with that level of precision. Why do vacuum canisters not have a cyclone on them? In the year 2023, why do we have to take an old bucket, and make our own vacuum cleaner for sawdust. We have alien technology in our cell phone, and they can't even sell us a working vacuum? Something doesn't add up.

[@TerrellMethvin]

Awesome video and great work. I love the way you used the table saw.

[@dalewolver8739]

Great job. Love that circle cutting technique

[@Rusty_ok]

Perfect dust collection from existing or surplus stuff.

[@paulbooij7594]

very nice, I hooked mine up to a 4" hose for my dust collector. I just stuck a 4"elbow in to mine in the side (facing to the side), and one in the lid. It did a great job. Took me 5 minutes to make. Your looks nicer though.

[@therealstanli]

this is a fantastic and smart design! It you think about the volume ratio, when you have cyclone, why not reduce the volume of the dry vac itself.

[@TheOffcut]

Thanks!

[@Muscleduck]

I like this idea a lot. Might just use it here in my cave. 1 remark tho: I wouldn't modify my shop vac permanently for this. I'd connect the hose to the top of the bin. I loved the technique you used to cut perfect circles a lot as well. Just shows me another reason to make a sled.

[@vicwelch9217]

Great table saw hack. To much work. I took a 55 gal metal drum with a removable lid and clamp. Cut two holes one for vac and other for planer or other tools. Works great. Not as pretty as your but works. Keep up the good work and be safe.

[@nathanwooldridge85]

I've got an old Dyson kicking around and you've got me thinking about if I can mod that for dust extraction!

[@TheOffcut]

haha I did that too before I made this one. You can check out the video kzbin.info/www/bejne/haSrdYODedCjhqc

[@rdragon6151]

GREAT video & design, best on KZbin I've seen! Like how you don't need a cart and how compact it is.

[@mp180170]

Genius modification I would say 👌🏼 kind regards from 🇬🇧 uk

[@hugobose2254]

good video Had you thought of Not cutting the bottom off the vac bucket, and drilling a hole through the bottom ??

[@jroseme]

Looks like I have another project to add to the list. Thanks for sharing!!! And for the no-nonsense video editing.

[@Sheltieist]

Nice job. Good idea, it doesn't add too much to shop vac foot print.

[@andremoel]

Nicely done 👍👍👍... i like the way you make the circle with the table saw.

[@bennythebrokerau]

Cracking design mate! I'll be trying it out in my shed. Although I might hack up the Ozito vac instead of the Ryobi just in case I get it wrong. Ha ha. Well done, great video will go and watch some of your others now.

[@trevcessna1723]

Awesome!! Good skills...I like the quality, flipping the board and finishing the hole from the other side!! I need a dust collector for my new sandblasting cabinet, I have an extra shop vac so this is perfect!! Thanks Bro!!

[@SimplyElectronicsOfficial]

Respect my friend. I would have liked to make a cone inside to get a stronger cyclone and thus better separation. Much like a Dyson.

[@transformationofthebride2295]

I have seen many videos...this is the BEST idea! 👏

[@ВасилийГудков-е6ч]

В этом проекте самая удивительная и уникальная часть - это огромное черное ведро. Оно не только имеет большой размер, но и толстые стенки, чтобы не быть смятым атмосферным давлением. А также две большие прекрасные защелки-клипсы, которые фиксируют крышку… Где же взять такое прекрасное ведро?! (Вопрос не имеет ответа)

[@Chokoso]

Well done. That was a clever design and a clean&nice excution

[@slaplapdog]

Great build, thanks for the clean presentation . You presented it does up and I watched it in double time,so I feel a little sick, but in a good way!

[@thunderbeast3976]

Mad genius 👏🏼awesome vid Mr.DJ spinning on the table saw 😂

[@What_Other_Hobbies]

Very good project. I checked the vac, but it is not available from US retailer. I will probably cheap out and use a smaller one.

[@clm5717]

That’s amazing! Should sell those if not already. I’d buy one!

[@MrWadim94]

I use the size 1 and 1/0 Mustad hooks to freeline for snook kzbin.infoUgkxzXmlErSqVAEGWFEKO530BvTqFDw53QW3 and they have been fantastic. The points are super sharp, and the hook is small enough to blend with my baitfish, yet large enough to land fish 30" or more. I also use these hooks when I'm pier or surf fishing with my kids. They tend to catch tons of smaller snapper, whiting, and catfish, and we get far fewer gut hooks with these Mustad in-lines, which means more of them survive after release. I was actually using these hooks when I caught my friend too, but I think that had more to do with the bait I was using ;-)

[@s.e.wagger3888]

WTF????? What has fishing got to do with making a shop dust vac??? And why would you let them go, ya' cruel bastard???? You're supposed to fish so you can eat them. Otherwise you're just being cruel!!!!