Workshop build log

Building My Thien-Baffle Dust Collector

These photos were taken more than ten years ago, when I was trying to improve the dust collection in our small woodworking shop. Nothing fancy — just plywood, PVC pipe, and a lot of trial and error.

April 2026 Dust collection Woodworking shop

This separator was inspired by J. Phil Thien's cyclone baffle design. I want to say a sincere thank you to Phil for sharing the idea so generously. His work helped many small workshops, including mine.

Why I built it

We already had a dust collector in the shop, but I wanted better chip separation before the dust reached the filter bags. The goal was simple: catch more chips, protect the collector, and make cleanup easier with materials I could build myself.

This build was done long before I started documenting projects more carefully, but it remains one of the most useful things I ever made.

Making the separator

Instead of building a full cyclone, I chose the Thien-baffle approach because it was simple, compact, and realistic to make with the tools I had at the time. The structure was made mainly from plywood, with a metal cylinder used as the main chamber.

It took a few adjustments to get the airflow right, especially around the inlet and the baffle gap, but after some testing the separation improved a lot.

Panel layout for the homemade Thien baffle separator — The main panels laid out before assembly, including the circular baffle opening and the inlet section.

Cut parts and baffle ring for the separator build — The baffle ring, top panel, and support parts prepared for assembly.

Handmade wooden support pieces prepared for the build — Small wooden parts made during the build, including support pieces for the shop installation.

Freshly painted wooden brackets drying before installation — The same support pieces after painting, drying before installation.

Building the collection box

Under the separator, I built a simple plywood collection box to catch the heavier chips and dust. It was easy to empty, easy to repair, and worked well in daily use.

Homemade dust collection box with separator mounted on top — The collection box with the separator body taking shape on top.

Dust collector separator connected with hose and PVC fittings — After connecting the inlet and outlet, the separator was ready for testing in the shop.

Installing it in the shop

The system was connected with PVC pipes and flexible hoses. It was not pretty, but it was practical and easy to maintain. For a working shop, that mattered much more than appearance.

I also made small wooden brackets to support the pipe runs and to help organize wiring along the wall.

Workshop wall with handmade wooden brackets supporting cables — Part of the wall routing, showing the handmade brackets used to guide cables neatly across the shop.

Close view of handmade wall brackets carrying workshop cables — A closer view of the wall-mounted brackets and cable routing.

Completed Thien baffle separator installed next to stacked lumber — The completed separator installed in position beside the wood storage area.

Dust collection system connected to woodworking machines in the shop — The full system in use with the main collector, machine connections, and the overhead pipe run across the shop.

Adding a remote switch

One detail I still like very much is the remote control switch I added for the dust collector. At the time, it felt like a small upgrade, but in daily use it made a big difference.

I built a simple control box around the contactor, protection devices, terminals, and a wireless receiver so the collector could be switched more conveniently from the workshop.

Even today, after more than ten years, that remote switch is still working.

Internal wiring of the homemade dust collector remote switch box — The remote switch control box during internal wiring, before final installation.

Installed dust collector remote switch control box mounted on the wall — The completed control box after wall installation and connection to the shop power system.

Why this project still matters to me

Looking back now, this was not a perfect build, but it worked, and it lasted.

It came from a real need in the workshop and was built with simple materials, patient trial and error, and a lot of hands-on work.

In a workshop, that is often what matters most.