Rigid Dust Deputy 2.5 Stacked Cyclone Vacuum using 2 gallon HD buckets

Cyclone directly mounted on top of Rigid vacuum
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updated November 23, 2024

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I put together this idea to build a cyclone right on top of my Rigid vacuum base using Home Depot 2 gallon buckets. This is done instead of building a vacuum cart that seems a popular solution. I wanted to get away from having a separate smaller bucket for my cyclone and having almost nothing go into the large vacuum chamber. I stacked two 2 gallon buckets with a hole between them and a filter mounted inside the bottom bucket. The vacuum itself was then left sitting on top of the top bucket. 

For this I used a Dust Deputy 2.5 and my old Rigid vacuum/blower that has the vacuum motor removable from its top.

It works! It worked a bit too well actually. The very short vacuum path caused so much suction that the small dust goes through the cyclone too easily and they get into the vacuum filter. I have to clean that filter more often then I hopped. The large particles do go to vacuum base which is great. I really need a second stage to get the smaller dust separated as well. I'm publishing this model hoping someone can improve on it. 

Hopefully this has enough images and info to give an idea of what this design looks like.

The included parts are a full set with extra pieces I designed as part of developing this. I didn't use all of them but include them since they could be useful to others.  

A few more important details:

  1. The vacuum filter I used is a Walmart Hart. I think the part number is 9035033.
  2. The Rigid vacuum is a wet/dry so it has a piece inside it that fill float up to avoid water overflow. This will get in the way  but the whole piece can be removed to allow debris to make it directly into the container.
  3. The design images from Fusion 360 don't show the buckets. The simplest explanation is
    1. The bottom funnel is installed on a bottom of the oneida cyclone and has a matching bolt pattern. There is a board between the cyclone and this funnel which fits the top of the Rigid vacuum base and should seal the cyclone to the vacuum. I put a think foam around the opening of the vacuum to make sure it seals.  The funnel is in intended to bridge the gap between the plate and the entry hole to the Rigid dust container. 
    2. The middle adapter goes on the bottom of the bottom bucket. It should be a snug fit to the top of the oneida cyclone. It is simply a large threaded insert. Make a hold large enough and put the bottom two pieces in this hold. Bolt on the large nut above it. The adapter is in two parts in order to make it easy to print. Each can be placed on the build plate with the threads going up and with not overhang issues so no supports are needed. Remember the middle piece of this is bellow the bottom bucket and the bucket is above this. Here again I put a foam seal to help avoid vacuum leaks. Inside the bucket you should only have the large nut. Hopefully the pictures will help.
    3. I usually put a pool net over the vacuum filter and it is a prefect fit as well and makes the main filter easier to clean.
    4. The top adapter goes on the lid between the two buckets and through to bottom of the top bucket. There is a washer provide and this will go between the lid and the bucket. You can put a foam seal but I found I didn't have too. The top bucket should only have the bold in it. 
    5. Finally the top bucket has nothing in it for me. I just site the vacuum motor on top and it seals naturally especially when running. The bottom base is wide enough to pull on the vacuum hose to move this thing around but if it gets stuck it is top heavy when empty and can flip over. 
    6. I hold it all together with some long bolts that squeeze the bottom plate with the bottom bucket. The bucket above it is held by the cover that snaps on. This way you can pull the cover off and deal with the filter. I made some brackets for this but I ended up using standard hardware to the rods to the bottom plate. 
    7. Also  shown in the full Fusion 360 image is the bracket that fits in the Rigid vacuum bracket. 
    8. You will need to put a cap on the original vacuum inlet. I wanted to design one but never got to it. I just stick a rag in there for now. :( 

Any questions send a message and I can add more picture or answer your question.

Hope this is useful to someone. 

Filter used: https://www.walmart.com/ip/Shop-Vac-Reusable-Ultra-Web-Cartridge-Filter-Wet-Dry-Vacuum-Use-Maximum-Fine-Dust-Filtration/16630457?classType=VARIANT&adsRedirect=true

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The author marked this model as their own original creation.

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