Completed system picture first. The system has a stock harbor freight dust collector that I modified to become a cyclone separator into an old 55 gallon barrel. It works with a low voltage relay and switch system to automatically turn on the collector when ever a blast gate is opened and vice-versa. The system collects dust at my router table, band saw, 3 sanders, drill press, table saw, miter saw and an assembly table outlet for power sanders.

A look at the completed dust collection on the miter saw.

I started by marking a level run from the exhaust of the collector to the wall where the air will exit the shop.

I drilled a 5" hole in the drywall with a hole saw.

After removing the necessary insulation I drilled a trough hole in the center of the 5" hole to the outside to transfer where the bricks needed to be removed.

I placed a 5" piece of duct centered over the hole I just drilled and traced out the area to be removed from the bricks.

I drilled several holes around the perimeter as I didn't have a 5" diamond hole saw. I then knocked it out with a hammer and cleared out the rubble.

I slipped the exhaust louver into the brick wall and into the garage.

It was attached with 4 screws and sealed off with white silicone caulking.

The exhaust pipe is 5" metal HVAC pipe which I sealed with foil tape and held to one another with a couple small screws.

I build a small box to act as a transition piece from the rectangular end of the dust collection unit and my 5" HVAC pipe.

Everything got foil tape and silicone caulking.

To make the brackets which support the pipe along the wall I took a small cross section of pipe and traced it onto some 3/4" plywood and on the band saw cut out shape about 5/9 of the way through the pipe as to make a pressure fit to get the pipe in and out of the holder.

All my cuts to length fro pipe were made on my miter saw with a standard combination blade. (it's a 12" saw)

The pipes are 4" PVS (sewer pipe) and the support brackets are held into place with 2 3" screws into the studs. The transition piece from the dust collector to the 4" PVS is a 4" to cast iron piece I got from lowes.

All of the joints are held together with PVC cement. Yes I know I didn't have to do this but it add a lot of strength and saves a lot of time during install. Also If I want to move anything I can just cut them apart and attach a coupler.

I traced out the profile of the pipe and to cut the hole in the blast gates I used the scroll saw as close enough works great for this project.

The spacer rails are tacked on with a few crown staples with the 1/8" hardboard gate sliding freely in the middle, with a hole in one side.

The top hole for the 4" PVS and the bottom hole for the tool drop are held together just with 4 screws in case they need to be taken apart ever. I glued on small pieces of hard board to the top and bottom side of both ends to act as grips to pull the gates open and closed.

A small section of 4" PVS was screwed in 3 equal points around the blast gate assembly.

This gate has a 4" flex receptacle screw onto it so it can be used with the router table, table saw, band saw or miter saw.

Everything gets sealed with caulk.

I made a 3 way split for my 3 small stationary sanders which all have small dust collection ports on them and go into 1 4" drop.

All 3 hoses get 2 screws in each to hold them in place.

A view from inside the sander station drop.

Lots of caulking.

The stationary belt sander needed a small plywood adapter to fit the hose and everything got caulk to seal them to the hose.

I found this product from Lee Valley called Loc-Line which is great from drill press duct collection because where ever you set it up to suck it stays in place.

I added some 1/2" plywood and a large 4" flex pipe receptacle for dust collection under my contractor table saw. Everything was sealed with silicone caulking after.

The low voltage (24vdc) magnetic switch that opens and closes the circuit, turning the collector on and off.

In here I installed a 24VDC relay to run the low voltage circuit and keep the dust out.

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