Lots and lots of dust to deal with

[Stagecraft]

I've been approached to crew up with a very large motion picture that will begin filming here after Christmas.
We would start building the main sets almost immediately.
They want me to bring in both of my Shopbots.
They would be used to cut patterns into 2,3 and 4 inch thick sheets of styrofoam which has been glued to 4x8 plywood sheets.
Between the main set and various other elements, both Shopbots would be cutting the foam and plywood for up to ten hours per day for around six months.
I know the machines are easily up to the task but I haven't yet figured on how to deal with the massive amount of foam dust that will be generated. Due to the nature of the stuff my 2hp dust collectors wouldn't be able to keep up and because we'll be using longish bits they may not work at all.
I'm thinking this requires some outside the box thinking and wonder if anybody here has had to deal with large quantities of styro? - Boyd

[cabnet636]

can you build a temp enclosure (room) and use filters with fan removal foam dust is nasty stuff

[Stagecraft]

Jim, building a temporary room will definitely be done but my concern was more on keeping the dust off the equipment and getting it out of the room and into the waste containers. The foam dust is a real pain, with it's static cling the stuff goes everywhere. - Boyd

[knight_toolworks]

time for a cyclone and a better dust skirt. that should solve most of the issues.

[danhamm]

Anti magnetics..or degaussing...like the old TV's had for screen static.

http://www.maurermagnetic.ch/005_E_demagnetizers_overview.html?gclid=CI3NudnD9q sCFQJZhwodSBbKBw

[zeykr]

Bounce dryer sheets

[jerry_stanek]

I have a Thien separator on my 2 hp dust collector I just cut a bunch of pink foam and 90% if not more ended up in the separator. I have a 30 gallon fiber trash can for the separator.

[cabindoors]

Make sure you pay close attention that the guide rails, racks and pinions stay clean.

[planman]

Time to bring on the cyclonic equipment...

http://exfactory.com/Equipment.aspx?type=cat&what=DC

Think used, they don't wear out... and they can be pretty cheap if you buy used.

(no affiliation with the link, just showing you where I shop....)

[jimboy]

I looks like dust = $ to me
Jim

[kevin]

Congrates on your contract

Sounds like a big budget . The question your asking is an extra long bit to long for the skrit to reach and get proper suckcion .You'll have to play a bit add an extion to the skrit you.ll have to play with it and make shure it doesn.t get caught in the bit.

This is a link http://www.busybeetools.com/products/CYCLONE-DUST-COLLECTOR-2-STAGE-1HP-CSA.html Its more then enogh power to do the job .The wider the hose the better the suckuction 5 inches minum 6 better but I think its to heavy .That will help with with stuff flying around .Ground for static
Use two vacums one for each machine shorter the distance the better .Could use one but for a project like this if one dies your still in bussiness plus less trips to the dumpster

Do you have suction if not think about investing if your doing that many sheets fast turn over is imporant I cant imange working with out one

[jimboy]

Yes turn-around is going to very important.
Jim

[carlcnc]

Boyd
surprised someone hasn't suggested this[maybe I missed it]
your obstacle is the depth of cut.
I would setup a way to blow compressed air into the kerf,
it will take some fine tuning as to size of tube,volume and pressure but,
I would start with say a 1/8 tube and about 60 psi aimed at the bottom of the cut ,as and angled down at the end of bit,
If yu can get the chips out of the slot even a 2hp collector should pick them up
Maybe Kent [Kent Dust Shoe] can help you out with a custom plate to hold said tube/nozzle
Carl

[kevin]

http://billpentz.com/woodworking/cyclone/index.cfm

This guy wrote the bible on vacums as far as I.am concerned .I remeber about 10 years ago reading this and it opened up my eyes

Also the vacum i mention the drum can be changed in under 2 min .Try that with a bag

[knight_toolworks]

http://billpentz.com/woodworking/cyclone/index.cfm

This guy wrote the bible on vacums as far as I.am concerned .I remeber about 10 years ago reading this and it opened up my eyes

Also the vacum i mention the drum can be changed in under 2 min .Try that with a bag
My first cyclone was one he built and sent to me.
remember 4 flute bits high rpms and fast feed rates cut foam the best.

[Stagecraft]

"Also the vacum i mention the drum can be changed in under 2 min"
Thanks for the input guys but I'm thinking this job will create dust on a whole different level.I have to have both my Bots moved, rewired and ready to run in a week and the expense of an industrial sized cyclone system would be out of my pocket, and that kind of money isn't available on this job.
The best solution we've come up with so far is a sealed temporary room with fan fed air on one side and an exhaust box on the floor at the other side of the room.
The dust will be blown off manually with compressed air towards the exhaust box which will have a large collection hopper downline with a capacity of around 300 gallons which will be drawn by a 5hp dust collector.
As always, any input is appreciated - Boyd

[kevin]

The busy bee one is only 500.00 stands 5 and half feet runs on 110 designed to be portable

With a fan blowing will it drive you nuts with the wind will it be a spray both set up ?

This is a good topic proper dust vacum is so important