I've been running a small woodworking shop out of my garage for about three years now, and I'm finally at the point where I need to upgrade my dust collection system. My current setup is a mess—literally. I'm using an old shop vac with a cyclone separator I built from a kit, but the fine dust just laughs at it and settles everywhere, including on my finished pieces.
I already tried adding a cheap WEN 3410 air filter I got on sale, but it only helps with airborne dust after I stop working. The real issue is at the source: my table saw, planer, and miter saw. I've been reading about building a central system with ductwork, but my garage is only about 20 by 12 feet, and I'm not sure if I can run rigid pipes without losing too much space. I looked at a used Delta 1.5 HP collector on Craigslist for $200, but the guy never replied, so that fell through. My budget is tight—maybe $400 max—and I have to keep the noise down because my neighbor's window is about ten feet from my workbench. Not sure if this matters, but I also use a lot of MDF and plywood, which I know is nasty stuff.
I've considered the Harbor Freight 2 HP model with a canister filter upgrade, but I keep reading mixed reviews about static pressure and airflow on smaller duct runs. I spent two nights sketching layouts with 4-inch PVC, which seems cheaper than metal spiral pipe, but I'm worried about static electricity buildup. Is that a real hazard or just something forum people scare you about? I also thought about just getting a better shop vac with a HEPA filter and a bigger cyclone, but then I'd still be dragging a hose around for every machine.
So here's my real question: for a small one-person shop like mine, is it smarter to go with a portable 2 HP dust collector with a short 4-inch hose I move from machine to machine, or should I bite the bullet and install a semi-permanent 4-inch PVC system with blast gates? And if I go PVC, do I really need to ground it, or is that overblown?
A friend of mine tackled a similar dust issue in his garage workshop, which is about the same size as yours—it was a mess too! He opted for a portable 2 HP dust collector and was surprised at how well it worked. After some testing, he found that he could effectively connect it directly to each of his power tools using a ducting system he built himself with 4-inch hoses. The key was the use of the right adapters to ensure a snug fit, which minimized loss of airflow. With a bit of ingenuity, he actually managed to keep the setup streamlined and easy to move around without needing a permanent installation.
About grounding — while it's often discussed, the actual risk of static buildup in PVC is usually considered manageable. My buddy opted to add a grounding wire for peace of mind, but many in the community report good results without it. If your garage is as cramped as you say, sticking with a portable system for now might give you more flexibility and save some space. Plus, with a little elbow grease, you could always improve the setup down the road if needed.