Just finished pouring the slab for my new 40x60x16 polebarn. All that remains is the driveway and installing electrical and lighting. In floor heat, 320a service... all the goodies. Found a deal on an Atlas 3ph 7.5hp compressor and will be setting up the 3ph converter in the next month or so. I have a 3hp Grizzly dust collector that was in my last shop and want to set it all up as soon as the weather breaks. In the last shop, I ran all 4" PVC (I know). Would like to set this one up correctly using metal ducting overhead but am concerned about the length of the runs. The dust collector will go in a room designed for "noisy stuff" at the back of the shop (14x24 buildout section). The duct will have to be routed from the DC up to the ceiling (16'), then run the length of the shop (40') with drops for 2 table saws, the jointer, chop saw, planer, and etc. The workshop area of my shop will be 28x40 so lots of goodies to plan for.

I know there to be lots of knowledgeable folks on the forum so hoping someone has advise on sizing the runs to keep the system as efficient as possible. Would love a cyclone at some point but don't know if it's in the budget for a while. So far thinking 6" main with 4" drops for equipment (all solid pipe and minimal flex). Grizzly site says the DC is pulling approx. 2300 fpm.

Anyone have any suggestions or comments before I start this endeavor?

Click the link below to download the file included with this post.

40x60_Floorplan.pdf

One more question... should have included it in the original post. The DC will be in a 10x10 enclosed room but I know it needs to vent. Trying to keep the noise level to a minimum and thus the 10x10 enclosed room (will be insulated with 2"xps on both sides of R13 insulated 2x4 wall). Can enclose the DC in a "Closet" inside the room and vent to either exterior through soffits or back into building, but want to keep noise levels to a minimum... How are you guys running the exhaust venting for your systems? Don't want to put the DC outside as I am in a neighborhood and the neighbors are not excited about my project already! What is the best way to muffle the noise levels?

The 10 x 10 room venting may not be needed. 3500 CFM in, 3500 CFM out. All thru the ductwork. You will have some heat build up with the fan motor. This can be vented to the shop if the shop can benefit from the heat, or to the outside if preferred.

Equal in and out also means you get to keep your heat and A/C in the building. It will be removed by the D/C, filtered, and returned on the low pressure side of the filter bags (bag fan).

Oh, and get rid of the 3hp unit. You will outclass that quickly, my guess. Go to oneida with your floor plan, price it out and see what you get. Expensive? Is your shop the cheapest on the planet?

I will contact Oneida for future reference, but at the moment I have stretched the budget on the shop. So, to understand, you recommend an additional duct for the DC exhaust back into the shop? I like that idea much better in keeping the heat where it belongs, but is there a way to muffle the noise levels?

Pay attention to your ceiling height. Larger dust collectors with more filter area tend to be taller.

I should be fine on height with 16' ceilings. Would I be smart in building a "Closet" to mount the DC in to control dust?

What was the result of discussions with Oneida? Were they helpful?

Oneida is a wonderful company. The sales rep who called me suggested a 5HP cyclone and new ducting - I am on the fence about replacing my current system as the one I have is paid for... I am not running a business - this is a home shop and so I have to figure out the rest of the budget.

I have read many of the posts on this subject here and other places, and the general gripe is that they feel as if too many people build their shop and consider dust collection a secondary expense that is not budgeted for - that is not necessarily the case as I am fully aware the necessity. In my case, I built the largest building I could afford and am trying to implement into the design any and all considerations for the future... I think I will start by a DIY ducting design and size it for a 5HP. I will use my 3HP grizzly system until I can save enough coin for the Oneida.

A problem I see with that is if your 3hp system cannot move enough air (and it won't in such a long run) you will get a lot of chips and dust dropping out in the main duct and may result in a clogged duct.

If there's one thing I've learned about setting up shop dust collectors it's that you should read as much information as possible before you begin. Seek out information from professionals and other woodworkers. Check out videos on YouTube/social media/etc. Good Luck!