I have a Delta 1.75 HP dust collector that I was thinking of upgrading to a cyclone. However, due to other tool purchase priorities, and the cost of a new cyclone with pipes (I got quotes in the $2,600 range for my shop) I decided to stick with the Delta for at least another year.

The performance of this unit is absolutely adequate using the short runs of flexible plastc 4" hose I connect it to various tools (table saw, bandsaw, jointer, planer).

However, I just finished my miter saw bench, and I need to run a dust collection connection to this very badly (my SCMS being the dustiest tool in the shop). For the saw I set up a two-tier dust collection approach: I am connecting a 2.5" flexible hose to the dust port of the saw, and have installed an open hood behind and underneath the saw to catch the additional dust and debris. This latter 4" pipe comes up from underneath the bench, and ties in with a Y connection and reducer to the 2.5" dust port hose.

I need a total run of 25' of pipe to get me from the dust collector to the miter bench. I have considered two options:

1) Use rigid PVC pipe (hung from the joists), including straight members and large-radius 90-degree sweeps to span most of the distance. Run grounded copper wire inside to avoid static issues. The benefit of this is that the pipe is smooth and should help maintain airflow. The downside of this is that I am not sure if I can find the proper diameter pipe that will work with the standard 4" flexible dust hose for making the connections at either end of the pipe.

2) Use standard 4" spiral-wire-reinforced dust hose all the way. The benefit of this would be that fitting the various connectors to the hose is no big deal, as these are already designed to fit. However, I worry that the spiral ridged hose will reduce the airflow too much, and the dust and debris won't get lifted to ceiling height and carried across the span I need.

So what do you think, which is the way to go? Any optinions appreciated.