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Build Your Own Cyclone System the Easy Way With Our
18-Inch Cyclone Dust Collector and Separator Kit

We produce a complete kit for building a 18"-diameter cyclone that represents the best performance that can be obtained for any unit in this size range. We also produce a matching welded, all-steel blower housing that comes complete with all assembly hardware for adding the motor and impeller, then attaching it to the assembled kit cyclone.

Both the cyclone and the blower housing are designed specifically to work well together, thus ensuring that you will have a reliable dust collection system that performs as it should when it is constructed and installed according to instructions and good practices.

Our cyclone design is based on the widely accepted "modified 1D2D" design that is commonly used in the cotton industry as well as in other applications because of its superior performance in separating fine dust from the air stream. The internal helix, a feature normally found on very large industrial cyclones, contributes greatly to improved fine-dust separation by dramatically improving air-flow stability.

What the Kit

The kit contains pre-cut and pre-formed parts that form the body of the finished cyclone:

  • Pre-formed 4.5" x 9" rectangular inlet,

  • Matching transition tube to convert 6-inch incoming round collection ductwork to the required 4.5" x 9" rectangular inlet profile.

  • Outer cylinder which forms the upper, exterior cylindrical part of the finished cyclone.

  • Inner cylinder (outlet) that carries exiting, clean air from the cyclone separator to the blower housing mounted at the top of the cyclone.

  • Separator cone which extends the centrifuge effect by managing the tornado-like air-flow vortex inside the cyclone. This accomplishes near-optimum removal of extremely fine dust from the air stream before sending the separated clean air up through the outlet tube to the blower.

  • Internal helix for improved internal air-flow management.

  • Dust chute at bottom for connection to dust container.

  • Screws, nuts, rivets with backing washers, all other hardware needed, and trim strips to dress up the joints at the top and bottom of the cone.

  • Complete, detailed, assembly instructions.

Pre-Cut Tabs
Easy Assembly

All tabs used to form the connection between the outer cylinder above the separator cone and the dust chute below it are already completely cut into final form so no further cutting is needed for assembly. Locating and retention tabs around the outer edge of the helix are also precut and ready to be formed for installation. This adds up to about 350 separate tabs that don't need to be cut or sawn individually, and each is cut with precision so parts fit together smoothly when you follow the directions provided with the kit.

Example of Precision Cutting (part of dust chute before folding)
(Actual part as shown is 2.3 inches high)

Locking Seams
Easy Assembly
Without Solder
The mating edges on the outer cylinder, inner outlet cylinder, and separator cone are already roll-formed using a standard HVAC pipe-lock seam so that they can be readily hooked together and flattened to form the cylinders, transition tube, and separator cone into their finished form.

The rectangular inlet is already folded into final form, and includes a standard Pittsburg locking seam on one corner to seal the inlet where the joint is located. The inlet transition tube that converts the 4.5" x 9" rectangular inlet to a round dimension that mates with normal 6" ducting has short slits cut to identify the precise location where the rectanglar end is to be bent so it can mate properly with the rectangular inlet. The length of the inlet transition tube is selected to ensure clean, smooth air flow into the cyclone for superior fine-dust separation inside the cyclone itself.

Example of Pipe-Lock Seam and Tabs at Bottom of Outer Cylinder
(Folded edge on left side hooks over mating edge on right before flattening with hammer
and steel backing block. Tabs along bottom edge for connecting to cone are about 5/8 inch wide.)

No Experience

All components in the kit have been carefully selected and designed so that it can be readily assembled by anyone with limited or no sheet-metal experience, using common, ordinary tools that are either found in the builder's workshop or readily obtainable from local sources such as hardware stores or lumber yards. With tools in hand, all you need to do is carefully follow the instructions provided with the kit.

Why Buy a Kit
Instead of Making My Own?

What is your time worth? What does it cost to drive back and forth to the hardware store and other businesses to find and purchase the appropriate hardware? What about finding trim pieces to make the end result look nice? How much would you have to pay for the sheet metal and special tools necessary to build a cyclone from raw steel stock? These individual needs add up very rapidly to some serious time and money! And that doesn't even include the soldering iron, solder, and other necessary items if you decide to cut your own metal and slit it to form the tabs for making locking seams, to say nothing of the time required for measuring and laying out the special arcs, dealing with the complex curve where the flat top and bottom of the sloping inlet intersects the circular wall of the outer cylinder (no, it is not a straight line. How's your skill in solid geometry?).

Example of Precision Cutting in Outer Cylinder Around Inlet Cutout
(Note "L"-shaped slit in corner. Try that with snips!)

A lot of very careful design work has gone into selecting materials and components, and developing the precision computer-assisted cutting instructions that command the numerically-controlled cutting machines that produce very precise parts that fit together well if you follow the instructions in the kit and measure carefully as you bend the tabs along joints between components. There are about 350 tabs in the entire kit, and some of the cuts around those tabs are difficult, if not impossible to make with readily available hand tools, as attested to by several seasoned HVAC sheet-metal workers who have remarked that it makes no sense whatever to do it the hard way when such a well-designed kit is so easily available.

Another Example of Precision Cutting Around the Air-Ramp Helix

What Else
Do I Need?

You will need the following items in addition to the parts provided in the kit:

  • Two pieces of 3/4"-thick medium-density fiberboard (MDF) or solid-core plywood about 24" to 26" square. From the center of each of these, cut two round donuts that are very close to 18.00" in diameter with a 9.00" hole cut in the middle. The donuts are used in the finished cyclone, and the outer portion can be used to hold the outer cylinder round during assembly.

  • A tube of polyurethane caulking/sealant available through commercial building supply houses. Do not use silicone caulk. Polyruethane has superior adhesion and strength, and can be painted.
  • A short length, as required, of 6-inch air-tight, flexible tubing or equivalent to connect dust chute at bottom to air-tight dust container at the bottom, beneath the cyclone.

What Does It
Look Like?

Here is a photograph of an assembled kit from our first run in 2003. It was built by Jay Albrandt, a fire fighter, who had no previous experience working with sheet metal. It does not include the trim pieces that are now provided in current kits. It is attached to a "budget blower" unit because blower housings were not available at that time.

Jay says that all he did was carefully follow the detailed instructions provided in the kit. Notice the smooth lines in the inlet transition tube as it converts from the 6-inch round collection duct to the 4.5" x 9.0" rectangular inlet into the upper cylinder.

First Assembled Kit from First Production Run
Seams and rivets are sealed with paintable polyurethane caulk/sealant

Another View from a Different Angle

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Updated September 23, 2004

©Copyright 2004, Clarke F. Echols and Clean Shop Air, LLC. All rights reserved.
No part of this material may be copied, reproduced, or redistributed in any form
without owner's permission.