We do a lot of sanding in our prefinishing shop, and the fine dust often clogged the filter on the shop vacuum. Cleaning the vacuum filter was messy and time-consuming, so I looked for an alternative. After considering expensive commercial filters, I decided to build my own out of medium-density fiberboard (MDF) and a 1-in.-thick fiberglass furnace filter.
Whatever size filter you choose (some are rectangular, some square) build the box around it for a tight fit. Holes in the top of the box receive the hoses from the sander and the vacuum, one on each side of the filter. The filter slides in from the front between wooden cleats. The door, attached with hinges, locks with screen-door hooks and eyes. I caulked all joints in the carcase and put a rubber gasket around the door to make it airtight.
I was surprised how well this simple and cheap device actually works. The vacuum filter still clogs, but now I clean it weekly instead of daily. A light tap on the furnace filter every few days helps keep it clear.
Drawing by Jim Richey.
Drawing by Jim Richey.
Fine Woodworking Recommended Products
DeWalt 735X Planer
The DeWalt 735X produced two faces perfectly parallel to one another, with surfaces far superior to what the other machines produced, thanks to its two feed speeds. At high speed, the planer works fast and leaves a smooth surface. But the slower, finish speed produces an almost glass-smooth surface. Knife changes are easy, with spacious access to the cutterhead from the top and a gib screw wrench that doubles as a magnetic lift to remove the knives. The 735X also has great dust collection, thanks to an internal blower that helps evacuate chips. The port has a 2-1/2-in.-dia. opening, but has a built-in adapter for 4-in.-dia. hoses. My only complaint is the location of the dust port. It’s on the outfeed side of the machine, and exits straight back. If you don’t pull the hose to the side, it interferes with material as it leaves the machine. The top is large and flat, so it’s a great place to set material in between passes through the machine.
Priced nearly $300 less than the DeWalt 735X, the Ridgid R4331 is an excellent value. Its three-knife cutterhead left wonderfully clean surfaces on plainsawn white oak and white pine. It did not perform nearly as well on curly maple as the 735X, but it created less tearout than all but one of the other machines (the DeWalt 734 was its equal). Knife changes were quick and easy with the provided T-handle wrench. Dust collection was good, assisted by an internal fan. The 2-1/2-in.-dia. port on the outfeed side of the machine is directed to the side, so the hose is out of the way. The planer’s top is flat and provides a good surface for holding stock between passes.
With its graceful curves, cabriole legs, and ornamental back splat, a Queen Anne side chair is a bucket list build for many woodworkers. Dan Faia had a very specific Queen…
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