Eagle 1654 lid reinforcements for Dust Deputy by cruztopia

Last crawled date: 3 years ago

A double layer plywood reinforcement for the Eagle 1654 20-gallon plastic drum assembled with 5/16" hardware. Has a 3" circle cut out of the center to match the bottom hole of the Dust Deputy.
Eagle makes several drums that are commonly used with Oneida's DIY Dust Deputy, and the Eagle 1654 is the yellow 20-gallon short and stumpy model. The 30-gallon 1601 and 1602 models also have a 19" diameter top, so I'm pretty sure this would work for those drums as well if you need something bigger. These plastic lids come warped and are never flat, so by sandwiching the plastic lid between two layers of plywood, you get a hefty and level base to mount the Dust Deputy on.
The DXF and G-Code were exported from VCarve and the material thickness is set to 0.728 inches to match the birch plywood from Home Depot. On your CNC router, set z-axis zero to the top of the plywood (not the spoil board). If you're using the DXF file, the 18 slots spaced 20 degrees apart are cut out on the bottom half are 0.450" deep to match the ridges on the bottom side of the plastic lid.
NOTE: The bottom edge of the top half needs to be chamfered to match the bevel of the plastic lid, and 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 20 degrees or more will work. If you don't have access to a such a bit or handheld router, just 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 a bit bigger.
Shopping List:

Dust Deputy cyclone dust separator: http://www.acehardware.com/product/index.jsp?productId=51625686


Eagle 1654 drum: https://www.zoro.com/eagle-salvage-drum-open-head-20-gal-yellow-1654/i/G3387526/


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


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


5/16" nylon lock nuts (qty 15): https://www.homedepot.com/p/Everbilt-5-16-in-Zinc-Nylon-Lock-Nut-15-per-Pack-802622/204325605


5/16" washers (qty 30): https://www.homedepot.com/p/Everbilt-5-16-in-Zinc-Plated-Flat-Washer-25-Piece-per-Bag-802314/204276370


zinc handles (qty 2): https://www.homedepot.com/p/Everbilt-6-1-2-in-Zinc-Plated-Door-Pull-15186/202034074


grip tape for slippery handles: http://a.co/2KYxZvv


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


Workshop WS25022A 20 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

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