Hose intake nozzle to Convert a Dyson DC22 into a high capacity Shop Vac for CNC router use.
I used a Dyson DC22 motorhead, i picked up for $5 from a Dyson used parts seller of a classifieds site.
I chose DC22 Motorhead because it has cyclonic stages, 1st is the intake canister for large shavings etc, 2nd is a larger inner cone, and 3rd are 14 small cyclonic separators for fine dust particulate.
If not for price and availability my 1st choice would have been the Dyson Ball with oscillating ends on the Cyclonic separators, claiming you do not need a final filter.
However the DC22 is not passing any noticeable fine dust particles.
I need a intake hose adapter, I made this one to accept a 40mm dia hose, you can make an adapter to reduce it to your hose size.
I have also included a PDF file in 300dpi to cnc cut a mounting flange for the canister and a bottom internal cyclonic end cap.
I used a 6mm thick clear perspex, I 4mm pocketed the sealing groves and flange canister locator.
I routed the top of the canister flat so I could glue a 135mm perspex disc that will accept a vacuum motor, you can make and design this your self to suit motor type.
I used a small low noise 600w motor I got from a $10 second hand hand held vac, I will replace this with a brush less motor when I find one.
I removed the trapdoor lid from the bottom of the collection canister and used a small grinder to remove the hinges and latches from the bottom to mount the flange.
For the dust collector I used a home brew fermenting drum with a screw cap lid.
you will need to adjust the outer flange diameter to suit your drum size.
The plastic used did not bond with Areldite 2 part epoxy.
I used silicon and superglue with baking soda for bonding.
I used a flat bed scanner to scan the intake on the canister at 300dpi
I imported the image into Illustrator and crated a vector of the intake.
I saved the vector and imported it into Rhino 3D V6
I used the "loft" command to morph a 40mm circle vector into the D shaped intake vector.
I then created a large surface area pad matching the 160mm outer diameter of the cyclonic canister for more surface area gluing using clear silicone and CA glue