Dust Deputy/Shop Vac Cart

 Read Reviews (2)

jp custom woodworks added on 5/21/2020

Maximize your shop vacuum with this cyclone separator cart. The cart is sized to fit a 14 gallon drum and shop vacuum which means emptying less. It can be built with less that one sheet of plywood and sized to fit any set up. The build is shown with a RIDGID NXT.

Directions

Follow the steps below to complete this project.

1

Cut the Rounded Profile

Cut the top piece as shown in the cut diagram. Using a string and pencil or a large round item as a template, trace an 11" radius (or similar) on each of the corners of the top piece. Using a jig saw, follow the outside of the traced line making sure to leave a small amount of material on the outside of the line. Once both sides have been cut, use an edge sander/ belt sander (can use an orbital sander as well) to remove material to sneak up on the traced line and create a nice smooth and rounded radius on each side.

2

Transfer the Rounded Profile

Cut the base piece as shown in the cut diagram. Using the rounded top piece created in step 1 as a template, trace the rounded corners on the base piece on all 4 corners. Again, remove the material on the outside of the line with a jig saw. Remember to leave a little bit of material outside of the line. To finish the radii on the base piece there are two options. If you have a router and a flush trim bit available, you can use the top piece as a template to match the exact profiles on each side of the base piece. If not, the same sanding steps in step 1 can be repeated to finish the radius on all 4 corners.

3

Make the Upright

Cut the upright to size using the cut diagram. Set your pocket-hole jig for 3/4"-thick material, and then drill pocket holes at the locations shown.

4

Make the Side Uprights

Cut the two side uprights to size using the cut diagram. Make sure your pocket-hole jig is still set for 3/4"-thick material, and then drill pocket holes at the locations shown.

5

Make the Gussets

Cut the two gussets to size using the cut diagram. Make sure your pocket-hole jig is still set for 3/4"-thick material, and then drill pocket holes at the locations shown.

6

Finish the Top Piece

Using the rounded profile cut into the top piece in step 1, cut the hole to accept the 14 gallon drum. The hole can be cut using a jig saw or a router and circle cutting jig. Optional: For additional shop vac accessory storage, cut/drill two additional holes sized to accept your shop vac extension tubes or other accessories (shown on the image for this step)

7

Make the Pads and Assemble Them

Cut the pads to size using the cut diagram. You may need to size these differently depending on what casters you use. Place them in the dimensions shown (from the center of the base) and secure them to the base piece using wood glue and brad nails. These can be secured with screws as well but be mindful of the hole pattern on your casters.

8

Assemble the Top Piece and Uprights

Using 1 1/4" pocket hole screws and wood glue, assemble the upright with the two side uprights, top piece, and gussets. Your assembly should look like the image shown.

9

Assemble Step 8 to the Base

Using 1 1/4" pocket hole screws and wood glue, attach the completed assembly from step 8 to the base piece. Align the assembly as shown in the image.

10

Bolt the Drum to the Base

Using the 14 gallon drum, drill 4 holes through the bottom in the pattern shown. Using the drum, transfer the hole locations to the base and drill matching holes. Once all of the holes are drilled, bolt the drum to the base using 1/4" bolts and washers.

11

Attach the Dust Deputy to the Drum

Using the Dust Deputy's instructions, fix the Dust Deputy to the cover of the drum as shown. Make sure the Dust Deputy is centered on the drum.

12

Attach your Shop Vac to the Cart

Using your shop vac, attach wood spacers, stand-offs or locating blocks that will be used to keep your shop vac from moving on the cart while you wheel it around. This step will be different for everyone. Example: For my shop vac I removed the wheels and created stand offs (shown in the image) to locate the posts that the wheels snapped onto.

13

Additional Accessory Feature

Optional: Cut two small blocks similar to what is shown that will be used to locate your shop vac extension tubes when they are stored through the top piece. Size them based on the diameter of your extension tube and make sure to test the fit before assembling them to the base. These will keep the tubes from shifting while moving the cart. Using your tubes to locate these blocks under the holes, attach the blocks using wood glue and brad nails. These can be attach with screws as well but be careful not to split the wood.

14

Attach the Casters to the Base

Fasten the casters to the pads that are fixed to your base. You may have to remove your shop vac and drum to make this easier.

15

Connection Tubing Recommendations

When selecting tubing or piping to connect your shop vac to the top of your Dust Deputy, remember to avoid any 90 degree connections or elbows. Long sweeping radii or 45 degree elbows are best. Air flow is restricted the tighter the turn that it needs to take.

16

Shop Vac Recommendations

When selecting a shop vac the power outputs and capacity are less important than the overall cfm (cubic feet per minute) specifications. Most larger floor tools will require a much higher cfm than shop vacs can provide, but a good shop vac with a higher cfm will work best for smaller tools and still be an improvement for larger ones (vs. nothing).

Tools Used:

Materials Required:

Wood Products:

(1) 3/4" Thick, Half Sheet, Plywood  

Hardware/Supplies:

(4) 3" Casters  
(1) Titebond Original  
(50) 1 1/4" Kreg Pocket-Hole Screws  

Parts/Cut List:

(1) Base, 3/4" x 40" x 23"  
(1) Upright, 3/4" x 19" x 23"  
(1) Top, 3/4" x 17" x 23"  
(2) Side Upright, 3/4" x 4" x 19"  
(2) Gusset, 3/4" x 7" x 7"  
(4) Caster Pad, 3/4" x 4" x 2 3/4"  

Extras:

https://www.amazon.com/gp/product/B0026GO5CA/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1 Visit
https://www.amazon.com/gp/product/B01FJ97E64/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1 Visit
https://www.homedepot.com/p/RIDGID-14-Gal-6-0-Peak-HP-NXT-Wet-Dry-Shop-Vacuum-with-Filter-Hose-and-Accessories-HD1400/304795071 Visit
https://www.amazon.com/gp/product/B002JP315K/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1 Visit

Discussion

You must log in to add comments

Login

    Become a Member

    Explore

    • Connect with the BuildSomething Community
    • See what others build and share your stories

    Contribute

    • Find inspiring ideas for your projects you can build
    • Get the step-by-step plans you need to succeed

    Share

    • Turn your projects into professional-looking plans
    • Share your plans you create on buildsomething.com

    OR

    CONNECT USING

    Already a member?
    Sign in!

    Kreg Tool