Dust Collection Systems and Solutions for Every Budget E-Book

Editors of Fox Chapel Publishing

• Herausgeber: Fox Chapel Publishing
• Kategorie: Lebensstil
• Sprache: Englisch
• Veröffentlichungsjahr: 2023

Seitenzahl: 131

Beschreibung

Keep your workshop and lungs safe! No matter how big or small your workshop space is, making your shop safe is essential for long-term health and preventing serious respiratory issues. Dust Collection Systems and Solutions for Every Budget is the ultimate guide to managing the dust in your workspace -- be it woodworking dust, epoxy resin dust, or metalworking dust -- and covers everything you need to know to be safe, from explanations of dust hazards and proper PPE to shop vacuums, shop-wide collection systems, air filtration systems, and location- and tool-specific dust collectors. Also included are helpful photos, graphics, and exploded views of different systems and shop layouts. Great for beginners to understand what precautions to take and helpful for experienced makers to be sure their space is up-to-par, this must-have resource is crucial for everyone with a workshop.

Leseprobe

© 2023 by Fox Chapel Publishing Company, Inc., 903 Square St., Mount Joy, PA 17552, 717-560-4703,

www.FoxChapelPublishing.com.

Dust Collection Systems and Solutions for Every Budget is a revision of Workshop Dust Control, published in 2010 ©American Woodworker. All rights reserved. No part of this publication may be reproduced in any form without written permission. Readers may create any project for personal use or sale, and may copy patterns to assist them in making projects, but may not hire others to mass-produce a project without written permission from the copyright holder. The information in this book is presented in good faith; however, no warranty is given nor are results guaranteed. American Woodworker magazine, Fox Chapel Publishing, and Woodworking Media, LLC, disclaim any and all liability for untoward results.

ISBN 978-1-4971-0415-0

PROJECT TEAM

Managing Editor: Gretchen Bacon

Acquisitions Editor and Contributing Writer for Metalworking and Epoxy chapters: Kaylee Schofield

Technical Editor, Metalworking: George Bulliss

Technical Editor, Woodworking: Charles Byers

Copy Editor: Kelly Umenhofer

Designer: Mike Deppen

Library of Congress Control Number: 2023943820

To learn more about the other great books from Fox Chapel Publishing, or to find a retailer near you, call toll-free 800-457-9112 or visit us at www.FoxChapelPublishing.com.

We are always looking for talented authors. To submit an idea, please send a brief inquiry to [email protected].

Table of Contents

Wood Dust Concerns and Safety

Using Shop Vacuums for Dust Collection

Shop Vacuums

Shop Vacuums for Portable Power Tools

Soup Up Your Shop Vacuum

Muffle Your Shop Vac

Dust Collection Systems

Central Dust Collection

Dust Collectors for a Small Shop

Dust Collections for Larger Shops

Cartridge Dust Filters

Tool Test: Cyclone Dust Collectors

Remote Switch for Your Dust Collector

Metalworking Dust Collection

Epoxy and Dust Collection

Tool Solutions

Dust Collection Tips

Dust Collection for Portable Power Tools

Dust Collection for Routers

Pneumatic Air Tools vs. Battery-Powered Tools

Air Filtration Solutions

Tool Test: Shop Air Cleaners

Air Scrubber Trio

No-Hassle Filter Cleaning

Electrostatic Prefilter Advantages

Wood Dust Concerns and Safety

ALLERGIES, FIRE HAZARD, MESS–YOU CAN AVOID IT ALL

There is no doubt that wood dust is messy and annoying, but now there also is research showing that decades of exposure to fine wood dust can contribute to nasal and lung cancer. These cases are among factory workers who breathed dust day in and day out for many years. For the weekend woodworker, however, allergies are a much more likely problem. Allergies can develop quickly, even among occasional woodworkers, and the symptoms worsen with increased exposure.

Besides the common sneezing attacks, allergic reactions can take the form of skin rashes, sinusitis, bronchitis, and asthma. The woods most likely to lead to reactions are red cedar, oak, redwood, mahogany, walnut, and many tropical species. However, all wood dusts are potential allergens, and the fine dust—10 micron and smaller—is the worst offender. If you’ve ever talked to a hardcore woodworker who’s been forced to abandon his shop forever because of allergies, it will make you a true believer in dust control.

Besides the health issues, we encourage dust control because dust is a fire hazard. Sparks can occur from faulty wiring or a grinder, dust can settle on hot light fixtures, plus there’s always danger from oily rags. All of these have caused numerous shop fires. If your shop is in your home, you should be doubly careful.

One frequently neglected fire-safety practice is to empty your dust collector after each day’s use. You don’t want a spark to smolder in that pile of dry dust.

If you want to do woodworking for the long haul, get your dust—especially the fine dust—under control. The best approach (in order of priority):

■ Wear an effective dust mask.

■ Use a vacuum to collect dust from finish sanders, routers, and other portable power tools (1 and 2).

■ Use a dust collector with generous felt bags on stationary machines (here).

■ Invest in an air scrubber (here).

Protective face shield

PERSONAL PROTECTIVE EQUIPMENT FOR WOOD DUST

Personal protective equipment is the first line of protection against the hazards of wood dust. Dust particles can enter your body through your mouth, nose, and eyes, which can become severely irritated from these fine wood dust particles.

Eye Protection

Eye protection comes in many forms, from Lexan clear safety glasses to clear rubber goggles that can be worn over prescription glasses. Another type of eye protection is a clear Lexan face shield.

Safety goggles

Safety glasses

Protective Masks

Dust masks come in various styles and purposes. The use of the general dust mask will do little to control the amount of wood dust you may inhale as you work on your project. N95 masks are often used to protect you from the hazards of wood dust.

Charcoal filtered mask

They should be replaced with a new mask every day so the buildup will be eliminated by daily replacement. Charcoal filtered masks offer a higher level of protection because the masks are made of pliable rubber to conform to the user’s face. There are two sets of adjustment straps that will create an airtight seal between the mask material and the user’s face skin. There are two canisters that have replacement charcoal filters that create an excellent protection from the hazards of wood dust.

N95 mask

What to Wear

Clothing can provide an excellent form of protection for exposed skin if you suffer from allergies related to forms of dust. Wear long sleeves and pants so dust does not build up on your skin and get trapped in your arm and leg hairs. Gloves that are form fitted and light weight can add another layer of personal protection. Splinters and other hazards from working with wood can be minimized.

Gloves can add an extra layer of protection from dust-triggered skin allergies.

Hearing Protection

Note: Even though hearing protection does not pertain to wood dust safety, it is important to to wear proper hearing protection when operating power tools.

Hearing protection can be provided in many forms, with the simplest being foam earplugs. These work well for lower noise levels and are very inexpensive. They are available in packs or two pairs or in bulk pack of 100 to 250. The next level of protection is the headband-style ear plugs. These consist of a plastic band that is placed over your head and soft rubber, ribbed earplugs can be inserted into your ears. When not in use, the band can be worn around the back of your neck, so they are accessible and ready to be re-inserted into the ears.

Headband-style earplugs

The simplest form of hearing protection is moldable foam earplugs.

Headphones provide the highest level of noise cancellation available. They are made of high-impact plastic with foam rubber inside each earpiece. A plastic headband is placed over your head and, for maximum protection, the entire ear must be fitted inside each earpiece. Note: Do not use electronic ear buds or musical earphones as a means of hearing protection in the workshop. These devices are meant to play music in your ears and have very little if any noise cancellation capability.

Noise-cancelling headphones offer the highest level of ear protection.

WORKSHOP ELECTRICAL SAFETY

Many home workshops are located in the basements or garages of woodworkers’ homes.

Electrical circuits of a home utilize a hot (black), neutral (white), and a bare copper ground wire. Many older homes lack the bare copper ground wire to disperse unwanted electrical energy into the ground utilizing a low-impedance path through the bare ground wire. If the home only has two-prong electrical receptacles, it is likely that the bare copper ground wire is not part of the electrical service. However, the bare ground wire may be looped in the receptacle box because the receptacle lacked a dedicated ground screw. The easy remedy is to purchase a new receptacle that will include a dedicated ground screw and replace the existing receptacle with a new one. The black wire is attached to the brass screw. The white wire is attached to the silver screw and the bare ground wire is attached to the green ground screw.

Homes that only have two-prong electrical receptacles likely do not have bare copper ground wires as part of the electrical service.

Note: If the existing receptacle utilized back wire connections, use the side screw terminals to connect the new device.

Many electrical main panels are in the basement, but the basement may not be adequately wired for the proper size circuits or the correct number of circuits that prevent overloading of existing basement circuits creating potential electrical hazards. The use of extension cords, although they are beneficial at times, should not be relied on as a permanent method of supplying electric circuits to power tools and woodworking equipment. These extension cords can be in disrepair, brittle, missing the third prong ground lug, and be under sized for the start-up and operating current amperage capacity. This can diminish the service life of the electric motor of the tool or cause overheating of the motor that is usually covered with dust, which can be a cause of ignition that causes a fire in the workshop.

New receptacles include a dedicated ground screw for older houses.

Basement floors can be damp, as water passes under most foundations in rainstorms, which is a hazard when using electrical tools and machinery. The single-phase circuits that the equipment and tools are attached to must be GFCI protected to prevent shock hazards. This can be accomplished with the use of GFCI receptacles or GFCI breakers in the main panel.

Garage workshops can be easy to move materials into and projects out of, because of overhead doors. Many garages are wired with multiple receptacles but may be on the same branch circuit. This can lead to power overloading of the existing circuit, interrupting the power every time, and tripping the circuit breaker of homes or blown fuses in much older homes. Seek the help of a qualified electrician or reliable information source to modify the electric branch service of the garage to prevent circuit overloading. Electric servicing for a garage requires GFCI protection for receptacles. If the garage construction is dated, the use of GFCI circuits may not have been required. Updating the circuits to conform to the GFCI requirements can be accomplished with the use of GFCI receptacles or GFCI breakers.

Avoid extension cords that are in disrepair, brittle, or missing the third prong ground lug, as they can cause electrical and safety issues.

Extension cords can be beneficial but should not be a permanent method of supplying electricity to woodworking tools.

SAFELY STORING AND USING FINISHING MATERIALS IN THE WORKSHOP

Safely using finishing materials in the workshop is a major consideration depending on the type of base materials that make up your finishing products. The use of solvent-based finishes creates three areas of major concern. The first is proper air ventilation so the buildup of fumes does not affect the user. Secondly, the fumes should not be allowed to travel through the rest of the home either, through the HVAC system or just by passive airflow. Lastly, make sure to safely store all solvent-based finishes to prevent from becoming a catalyst in the event of a fire.

Air Ventilation

Proper air ventilation in a basement workshop may easily be accomplished by adding an exhaust fan over or near the finishing area. This exhaust fan needs to be large enough to remove the unwanted fumes in the air through a straight duct (usually 4" diameter) to the outside of the basement. Be sure not to locate it within 4' horizontally of any window above the exhaust exit. A louvered exhaust termination on the outside of the house will prevent insects from entering the duct.

For basement workshops, install an exhaust fan over or near the finishing area to remove unwanted fumes.

A louvered exhaust vent on the outside of the house will prevent insects from entering.

Storing Finishes

Paint finishes are predominantly sold as water based but are still available for sale at paint retail outlets in oil base in the quart-size containers only. This change occurred in the 1990s when it was determined the VOC (Volatile Organic Compounds) was too high and the government passed legislation to limit their container size from gallons to quarts only. Oil-based finishes such as paints, stains, and clear coats require solvent-based thinners and cleaners. These are very harmful in closed environments and can be extremely flammable if exposed to high heat or open flame. Manufacturers do produce an odorless solvent-based thinner, which is used in the furniture repair business. If it’s available to you, consider purchasing it.

When working with solvent-based thinners and cleaners for oil-based finishes, take proper precautions as they be extremely flammable and harmful in closed environments.

Disposing of workshop rags with solvent-based finishes needs special attention. If they are left in an open container with paper or other combustible materials, the rags can self-combust and cause a fire in the workshop. If solvent-based rags are stored in the workshop, keep them in an airtight metal can with a lid to prevent the room oxygen from being one of the three catalysts to support a fire.

Solvent-based finishes in the workshop need to be stored in a metal cabinet, preferably a fire-proof model for best protection. A heavy-duty metal cabinet will work; however, a wood cabinet or drawer is not safe!

Keep solvent-based rags in an air-tight metal can with a lid to prevent the rags from self-combusting in the workshop.

Fortunately, today almost all finishes have a water-based option. This reduces the odors and eliminates the need for solvents to thin and clean solvent-based finishes. In the end the woodworker should choose materials that will provide the safest environment in the workshop.

Store solventbased finishes in a metal cabinet in your workshop.

Using Shop Vacuums for Dust Collection

The first line of defense against woodshop dust and debris is the shop vacuum. Use it to pick up the dust and chips produced by your woodworking machines. You also can connect most shop vacs to portable power tools and small woodworking machines, to collect the debris as it’s created.

A large shop vac makes short work of this mess of chips. A smaller machine would be liable to choke, however.

Shop Vacuums

HOW TO CHOOSE THE RIGHT VACUUM FOR YOUR SHOP

If you haven’t test-driven a shop vacuum in a while, get ready to be impressed. These aren’t Grandpa’s machines. Their filtration is better, their motors are quieter and their power is outstanding.

Choosing the right vacuum for your shop is not easy, though. There are so many models! We’ll cover some broad categories of vacuums so you’ll get an idea of what your budget will buy. We’ll also take a closer look at a few selected vacuums that you may find useful in your shop.

NOT JUST FOR CLEANUP

These days, workshop vacuums have two main uses: general cleanup and dust collection from small tools. The latest sanders, routers, plate joiners, and router tables have dust ports for hooking up to a vacuum. Teamed with a dust collector for your tablesaw, planer, and jointer, a good vacuum should capture most of the small, unhealthy dust particles these tools make before the dust becomes airborne.