Eagle 1654 lid reinforcements for Dust Deputy

thingiverse

A sturdy plywood reinforcement for the Eagle 1654 twenty-gallon plastic drum, assembled with 5/16" hardware. The center features a 3" circle cut out to match the bottom hole of the Dust Deputy. Eagle produces several drums commonly used with Oneida's DIY Dust Deputy, and the Eagle 1654 is a yellow twenty-gallon short and stumpy model. I'm confident that this reinforcement will also work for the thirty-gallon 1601 and 1602 models, which have a nineteen-inch diameter top. The plastic lids come warped and are never flat, so by sandwiching the plastic lid between two layers of plywood, you get a sturdy and level base to mount the Dust Deputy on. The DXF and G-Code files were exported from VCarve, with the material thickness set to 0.728 inches to match the birch plywood from Home Depot. On your CNC router, set the z-axis zero to the top of the plywood (not the spoil board). If using the DXF file, the eighteen slots spaced twenty degrees apart are cut out on the bottom half and are 0.450" deep to match the ridges on the bottom side of the plastic lid. Note that the bottom edge of the top half needs to be chamfered to match the bevel of the plastic lid. I chose to do this manually instead of on the CNC machine since I only had a flat end mill bit to work with. Any bevel/chamfer router bit that's twenty degrees or more will work. If you don't have access to such a bit or handheld router, simply decrease the outer diameter of the top half (the one without slots) by 1/2" and it'll fit, but the gap between the plywood and the brim of the lid will be slightly larger. Shopping List: 1. Dust Deputy cyclone dust separator: http://www.acehardware.com/product/index.jsp?productId=51625686 2. Eagle 1654 drum: https://www.zoro.com/eagle-salvage-drum-open-head-20-gal-yellow-1654/i/G3387526/ 3. birch plywood: https://www.homedepot.com/p/Birch-Plywood-Common-3-4-in-x-2-ft-x-4-ft-Actual-0-728-in-x-23-75-in-x-47-75-in-1503006/202088919 4. 5/16" x 2-1/2" hex bolts (qty 15): https://www.homedepot.com/p/Crown-Bolt-5-16-in-18-tpi-x-2-1-2-in-Zinc-Plated-Hex-Bolt-87176/204960788 5. 5/16" nylon lock nuts (qty 15): https://www.homedepot.com/p/Everbilt-5-16-in-Zinc-Nylon-Lock-Nut-15-per-Pack-802622/204325605 6. 5/16" washers (qty 30): https://www.homedepot.com/p/Everbilt-5-16-in-Zinc-Plated-Flat-Washer-25-Piece-per-Bag-802314/204276370 7. zinc handles (qty 2): https://www.homedepot.com/p/Everbilt-6-1-2-in-Zinc-Plated-Door-Pull-15186/202034074 8. grip tape for slippery handles: http://a.co/2KYxZvv 9. silicone sealant (optional). The bottom flange of the Dust Deputy can also be warped and bolt pressure is usually strong enough to give you an air tight seal, but if not, put some silicone on it before bolting it down. https://www.homedepot.com/p/GE-Silicone-II-2-8-oz-Clear-Window-and-Door-Caulk-GE500-3TG/100179996 10. Workshop WS25022A twenty-foot 2-1/2" hose: Your original short hose will go to the Dust Deputy so you'll need a long hose to vacuum with since your shop vac will be stationary: https://www.ebay.com/itm/111868446867 11. Fosmon remote power switch: Because walking back and forth to turn on/off the shop vac is a waste of time: http://a.co/b7xsHRO