Homemade dust separators often suffer from the same deficiency. Dust makes it through the separator proportional to the dust collected by the separator. As dust fills the container, the airflow agitates the settled dust as it is in nearer proximity. While the separator may operate at 99% efficiency when empty, as it fills, efficiency may drop to 70% or lower.

This project solves this problem with the addition of a baffle (which has been done many times before), along with an extended outflow pipe with many smaller holes drilled in its side to disperse the outflow pressure. As you will see, this allows for high efficiency, even when nearfull.


Related Links
=========================

* [Project Article](https://jeffreydking.com/articles/dus...)
* The idea to join 2 buckets originated from [Chris Notap](ttps://   • How to Make ● Simple Cyclone Dust Col...  ).
* The outflow pipe holes evolved from a shop vac muffler video by [Wood Crafting Place](   • How to Reduce Shop Vac Noise by 50%  .
* [J. Phil Thien](http://www.jpthien.com/cy.htm) is responsible for the baffle innovation in dust separators.


Materials List
=========================

* [5gallon bucket](https://www.homedepot.com/p/5galPai...) (x2)
* [Plywood](https://www.homedepot.com/p/2332in...)
* [2inch PVC pipe](https://www.homedepot.com/p/2inx10...)
* [2inch PVC 90degree elbow](https://www.homedepot.com/p/DuraCorp...)
* [2inch PVC coupling](https://www.homedepot.com/p/Charlotte...)
* [2inch PVC plug](https://www.homedepot.com/p/Charlotte...)
* [Silicone caulk](https://amzn.to/3dg3fxM)
* [Small toggle clamp](https://amzn.to/2M9ypeo) (x3) optional


Tools List
=========================

* [Utility knife](https://amzn.to/2M8PF3m)
* [Cordless drill](https://www.homedepot.com/p/RYOBI18...) or drill press
* [Circular saw](https://www.homedepot.com/p/RYOBI18..., [handsaw](https://amzn.to/2X9v3hJ), or table saw
* [Jigsaw](https://www.homedepot.com/p/RYOBI18...) or bandsaw
* [23/8 inch hole saw](https://amzn.to/2Any4BT)
* [Compass](https://amzn.to/36FnF0H)
* [Halfround hand file](https://amzn.to/2XJOZ9M)


Chapters
=========================
0:00 Introduction
1:13 Prepare the Separator Bucket
1:33 Baffle & Outflow Support
3:51 Outflow Pipe
4:38 Inflow Box
7:44 Final Assembly
9:10 Testing It Out
9:33 Conclusion


Video Sponsor
=========================

This video is not sponsored.


About Jeffrey D. King
=========================

I am a child of God, a husband to an amazing wife, a father of 4 daughters, an elder in the [PCA](https://pcanet.org/), an API architect, a woodworker with 3 bad fingers, and a parttime snake wrangler. I am square and cheap and laugh at my own dad jokes. I always think I am right because if I didn’t, I wouldn’t think it.

If you like approachable woodworking videos, please consider subscribing to our YouTube channel. Thank you sincerely!


Social Links
=========================

* [Website](https://jeffreydking.com)
* [YouTube](   / @jeffreydking  )
* [Twitter](  / jeffreydking  )
* [Instagram](  / thejeffreydking  )
* [SubscribeStar](https://www.subscribestar.com/jdk)
* [Amazon Wish List](https://www.amazon.com/hz/wishlist/ls...)


Credits
=========================

* Logo screw icon by [Lorc](http://lorcblog.blogspot.com/).
* Header and outro images by [Jon Sailer](https://unsplash.com/@eyefish73)
* Like overlay by [Creative Content Media](   • LIKE BUTTONS | GREEN SCREEN ANIMATION...  )
* Subscribe overlay by [MrNumber112](   • Free Download: Subscribe Button + Not...  )
* Music by [John Deley and the 41 Players](http://www.the41players.com/)