I finally finished my DC modifications!!!
I'm still playing around with shop setup, so I wanted to stay portable. A Pentz Cyclone is on the list, but that's further down the road.
I began with the Steel City 1 1/2hp 65200 DC a couple years ago, because it was the only DC I could find that had a 6" inlet, 6" hose from the blower to the drum, 1 micron bag, large chip capacity, and ran on 120V. I started by tearing out the 4" reducing rig inside the blower, and the CFM went through the roof. I bought a 10' length of flex hose from LV and modified the ports on my tools to 6".
My DC worked great, but like all dust collectors, as the bag clogged the CFM dropped. I investigated seperators, but wanted to keep the small footprint and mobility. I decided to build a thein baffle within my collector.
Underneath the inlet on the drum is the baffle, made out of 3/4" ply. the openning is 1 1/8", 240 degree around the circumference. At the top of the drum, i built a lid with a 8" dia pipe that projects 1 1/2" below to further reduce the amount of dust going to the filter and to affix an adapter to mount the Craftex pleated cartridge filter. (The picture is of my first attempt with a 6 1/2" dia pipe and a 4" drop, but the CFM dropped too much, so I went to 8" with a 1 1/2" drop , as per Phil Tein's suggestions). The lid is 3/4" ply sandwiched between 2 pieces of 1 1/2" pine. I wrapped a bicycle tire inner tube around the bottom ring to seal it into the collector.
I attached some pics of my jointer and planer after dressing some cherry until the 6.3 Cu Ft (175 litres) bag was near full. For those with the Delta 50-760, that's 2 1/2 bags full. As you can see, very litle escapes, leaving the floor and machine fairly clean. THe jointer is a 6" pick up, and the planer is a 5"-6" adapter pickup.
This is not a cyclone, so some of the fine dust still goes into the filter. But, the filter pops off easily, I put it outside, turn the crank, pick it up and put it back on. I have no way of measuring actual CFM, but this setup far exceeds standard 4" models, and should work well enough until a Pentz Cyclone replaces it down the road.