Nice job William.
My DIY dust system build and install stands me roughly the same money (for a similarly sized shop), plus a little more because i went for a new fan and 4kW motor, and had to install a VFD to run it from our low amp (Irish) single phase supply. There's several others on the site here that have also built their own systems.
There's an album of my build pics here :
http://www.gallery2.clearvuecyclones...ade/?g2_page=1 There's a series of build photo albums there (the Clear Vue forum from the Morgano days) from others that built systems to Bill Pentz's drawings which are here too:
http://billpentz.com/woodworking/cyclone/projects.cfm Bill's philosophy is very much that the DIY route makes it possible to get there for very moderate money.
It's a really important principle. Lots buy very marginal dust systems (with 1 1/2 or 2 HP fans - and then expect them to pull through ducting with predictable results) at high prices from the branded retail suppliers - when in fact it's possible by buying carefully and going DIY to build a 5HP premium performance system with a 15 or 16in BC centrifugal impeller and 6in or 160mm ducting that has the potential to take almost all of the hassle out of the dust issue for very little more. (or even less) It's not just about moving lots of air, big fans also have the pressure capability to deal much more effectively with the inevitable e.g. restrictive machine ports and the like that are not easily modified.
The US market may in detail be a little different, but some principles that helped keep my cost right down included:
1. DIY - take it steady. Doing the research means you end up understanding your system properly. Bill P's pages are a goldmine:
http://billpentz.com/woodworking/cyclone/index.cfm
2. Buy used where feasible. There seems to be quite a bit by way of suitable fans, cyclones and motors that come up used in the US. (unlike here in Ireland)
3. Don't buy ducting from branded retailers that apply huge mark ups. Spiral steel at trade rates from manufacturing (it's only a simple rolling and seaming machine that makes the ducting) suppliers costs only about $15/3m run for 6in dia if our prices translate to the US. (and the US is usually cheaper) Fittings are equally cheap. Retailers and easy access websites may mark up x4, and clip together Nordfab style ducting while a real luxury is similarly more expensive. PVC it seems can be bought right too.
4. Even if you don't fancy fabbing a cyclone most manufacturing ducting suppliers have fab operations where they build ducting, fittings and other stuff to order. You need to go armed with a drawing (see the Pentz link for a basis from which to prepare one) and to know exactly what you want (these are high output fab shops and not HVAC engineers - and they won't appreciate time wasting), but they typically bang cheap and cheerful sheet metal stuff out so well priced its unbelievable. (i got the cyclone body rolled from galvanised sheet steel, the spiral and the inner tube cut to size and built the cyclone myself)
5. Spot pick the stuff you buy new. I bought a fan and blast gates from Clear Vue, and new motor and VFD, and a couple of filter cartridges locally - basically because we have no used market in that sort of stuff.
Finally don't underestimate the work involved - but do be aware that even if you buy the dust collector that it's the ductwork install that is the heavy end of the labour….
cyclone + fan assy on floor 1-7-11.jpg workshop ducting etc 7-7-14.jpg ductwork in progress 1-9-11.jpg fan on floor 22-6-11.jpg fan in situ 31-10-11.jpg