SAVE YOUR LUNGS! Woodworking Ceiling Mounted Dust Filter - How to Make

How to Build a Ceiling-Mounted Dust Filter for Woodworking

Materials Needed:

• Sheet of 3/4 inch standard plywood
• Circular saw or table saw
• Craig Accu-Cut system
• Dewalt cordless saw
• Router
• Miter station
• Forstner bit
• Bandsaw
• Chisel
• Corner routing template
• Clamps
• Screws (2-inch, 1 1/4-inch)
• Dap caulking
• 3/4 inch piping strap
• Tin snips
• Eye bolts
• Turnbuckles
• Quick links
• Drill

Step 1: Prepare the Plywood

1. Cut the plywood sheet into pieces according to the required dimensions for the top, bottom, and sides of the air filter box.
2. Use the Craig Accu-Cut system to make precise cuts if your table saw cannot accommodate the full sheet.
3. Trim the pieces to final size if needed.

Step 2: Create the Circular Openings

1. Use a circle cutting jig to mark and cut out circular openings in the top and bottom pieces for the fan and filters.
2. Cut out the openings with a router, ensuring a clean and precise cut.
3. Mark and cut slots on the side panels for interlocking the pieces together.

Step 3: Assemble the Box

1. Sand all the panels thoroughly to remove any rough edges.
2. Use a corner routing template to round off the corners of the panels.
3. Test fit the panels together to ensure they align properly.
4. Glue and screw the panels together to form the box structure.

Step 4: Mount the Fan and Controls

1. Disassemble the fan and remove the stand and controller.
2. Determine the placement of the fan and controller on the box.
3. Create a niche for the wiring to pass through.
4. Mount blocks underneath the fan to secure it in place.
5. Attach the controller securely to the box.

Step 5: Seal the Joints

1. Apply caulking along the inner edges of the box to seal the joints.
2. Let the caulking dry overnight to ensure a tight seal.

Step 6: Mount the Filters

1. Cut piping straps into small pieces to create mounting brackets for the filters.
2. Attach the brackets to the box using screws.
3. Insert the filters into the box and secure them using the brackets.

Step 7: Install the Ceiling Mounting Hardware

1. Drill holes for the eye bolts and turnbuckles on the top of the box.
2. Open up the eye hooks and attach them to the box.
3. Secure the turnbuckles and quick links to the eye bolts for easy ceiling mounting.

Step 8: Ceiling Installation

1. Hang the dust filter box from the ceiling using the mounting hardware.
2. Use a level to ensure the box is hanging straight.
3. Adjust the turnbuckles to level the box.

Step 9: Electrical Setup

1. Connect the fan to a power source using an extension cord.
2. Use voice commands or manual controls to operate the fan and adjust the speed.

Step 10: Final Touches

1. Test the airflow and functionality of the dust filter.
2. Make any necessary adjustments to ensure optimal performance.
3. Enjoy cleaner air in your workshop and improved lung health.

By following these steps, you can build and install a ceiling-mounted dust filter for woodworking to keep your workspace clean and your lungs protected.