Spring Shop Project: Completed - Air System

[Jim Becker]

In a thread I started not long ago, I asked about what folks would be doing for "spring shop improvement projects" and indicated that mine was to finally get the piping in for my air system...using hoses was getting old. Well, I managed to complete it this week using a few evenings and some time earlier today for the final touches. This should really make a difference, not just in convenience, but also in "air quality", especially for spraying finishes since I decided to take the "overkill" route with filtration, etc.

Type L copper was used...58' of it almost to the inch. Coming from the DC/Compressor closet, the system branches to both ends of the shop following the main DC trunk and has 2 drops in the south end, one in the middle and two in the north end. The entire system slopes back to the closet in case any moisture gets by the filter(s) with a loop of flex to enable easy draining.

Below are a few pictures of the installation:

The compressor was relocated as part of this project to get it out from in front of the breaker box (code) and provide a convenient mounting location for the filtration and auto-drain. The 240 circuit was also moved, but that was very simple since it's just to the adjoining wall and still next to the breaker box...same wire, same box, same outlet. (I think I used different screws to mount it, however... ;) )
The filters and auto-drain are mounted on the backer board. Both of those black cylinders are filters...one is a dirt/water filter and the other is a coalescing filter to also insure any oil stays put. The IR auto-drain that I picked up from EBay not long ago is mounted just below them. Works great!
Because the compressor is now located where the cyclone filter used to hang, said filter needed to be relocated. Square to round adapters were purchased and the cartridge assembly was hung in the corner where the compressor used to live. This is a MUCH better arrangement and leaves full access to everything.
This is a picture of the drain connection at the bottom of the compressor. I sliced up an old hose and used new ends to make assembly simple...tape the connectors, screw them into the fittings and then connect the hose with little hose clamps. This also eliminates the chance of a leaky quick-connect.
The next post will contain a few more pictures...of some drops.

[Jim Becker]

Additional Pictures:

This set of air drops at the north end of the shop provides a regular outlet (on the bottom) and a special filtered and regulated drop for spraying finishes with my HVLP conversion guns. Putting the regulator on it means I no longer need it on the gun which makes it fit into smaller places. The white thing is an additional drying filter to insure the air has no moisture going to the gun. This little construction isn't pretty, but it will work out well for my needs. That standard drop will also make it easy to bring air to the tractor bay or out to the parking area for auto service.
This drop is over my bench area
And finally, this drop over the lathe gets a lot of use, especially when hollowing.

[Ken Garlock]

Jim, it looks like a nice tidy job. I do have one observation. On my compressor the compressor pulley is also a fan to blow air over the compressor. With the pulley cage close the back wall, are you going to get sufficent cooling air flow over the compressor?

Looks good :cool:

[Dennis McDonaugh]

Man Jim, the plumbing wasn't that professional at the Ford dealership I worked at. I'm still dragging a hose around....a stiff, short, always tangled hose to boot! :p

[Jim Becker]

Jim, it looks like a nice tidy job. I do have one observation. On my compressor the compressor pulley is also a fan to blow air over the compressor. With the pulley cage close the back wall, are you going to get sufficent cooling air flow over the compressor?

The fan/pulley is nearly 4 inches from the wall. I don't think there is any air flow problem...and the compressor rarely runs.

[Mark Singer]

Jim,

That looks like a great system! You really did a great job!
Did your Oneida come withe the Becker option or did you order it without since you have it already?:confused:

[Jeff Sudmeier]

Jim, it looks like you have a great air system set up there! I don't yet have a decent compressor, but I have saved this post for reference for when I get one and have to run my lines.

[Per Swenson]

Jim,

Nice Job.
What's next?
How about one of those dark blue and green
air sanders.

Per

[Kelly C. Hanna]

Looks great to me Jim. Smart idea to put the regulator & filter in the line for your spraying needs. What are you going to do to replace all the fun you had dodging hoses on the floor? :D:D:D

[Jim Becker]

How about one of those dark blue and green air sanders.

Nice idea, but not really necessary...the 150/3 and Rotex work so well and I'm a "very low volume" shop, as it were! ;)


Did your Oneida come withe the Becker option or did you order it without since you have it already?

Mine required that option...although I haven't quite figured out what it is and how it works yet... :o


What are you going to do to replace all the fun you had dodging hoses on the floor?

With any luck, I can spend more time tripping over projects... :p


I'm still dragging a hose around....a stiff, short, always tangled hose to boot!

At least change your hoses. Flexeel (http://sawsndust.com/r-flexeel.htm) is wonderful...very flexible, even at low temps.

[Russ Massery]

Nice job, Jim I used 3/4" sch40 pvc in my last shop worked great. I haven't done it yet in this shop but I do miss having not to trip over the hoses on the floor.

[Jim Becker]

Nice job, Jim I used 3/4" sch40 pvc in my last shop worked great.

Russ, you do know that PVC is not rated for compressed gasses?...Be really careful that nothing smacks that pipe when it's cold.

[Alan Tolchinsky]

Jim, That looks like a nice job. Do you like sweating pipe? I do and was almost happy to find an outside water pipe had burst over the winter. It gave me a chance to do some soldering.:) I'm not sure if I'm going to be at my location for long or I'd be doing an air system too. I like that compressor. What size is it? Alan

[Jim Becker]

Do you like sweating pipe? I do and was almost happy to find an outside water pipe had burst over the winter. It gave me a chance to do some soldering.:) I'm not sure if I'm going to be at my location for long or I'd be doing an air system too. I like that compressor. What size is it?

NO! I hate sweating pipe and only do it when it's necessary. The compressor is an IR 60 gallon unit that I picked up early last year from Tractor Supply when they were on sale for $499.

[Kelly C. Hanna]

Ahh...Tractor Supply....now that's a fun store!!

[Ken Waag]

Jim,

Very inspiring setup. Guess I'll add that to my shop improvement list (finish one, add two seems to be my motto).

That compressor is a beaut! If I see that for $499, I think I'll jump. I put my compressor in as an aside thinking I'd use it now and again. Its turned out to be one of those tools that you find a hundred uses for, so now I'd like to upgrade a bit. I did at least spring for a retracting hose reel so I'm not tripping over hoses like some ;)

Hey, thanks for the pix and ideas!
Ken

[Jim Becker]

Ken, even at the normal price most places sell it ($549 or so), that IR compressor is a good buy. That's not much more than the units sold at the 'borg and is a much better constructed compressor with more serviceability.

[lou sansone]

Russ, you do know that PVC is not rated for compressed gasses?...Be really careful that nothing smacks that pipe when it's cold.

I agree with jim on this one. I have used copper all over factories where I have been a plant engineer, without any incident. I did have a system that I designed for another military application that used hundreds of feet of clear 2 inch pvc pipe. someone did smack it when it was depressurized and I did not know it at the time. Upon pressurization, that hairline crack failed and talk about an atomic bomb going off !!!! not a good thing

nice job in the air install jim

lou

[Wes Bischel]

Well Jim, I have you to thank for giving me the "kick in the behind" to get my system up and running. No where near as impressive as yours - just a small "Y" set-up - no where near 58'!

The new layout of the closet looks like it will make access to everything much easier - well worth the investment in time.

OBTW - is the auto-drain activated by a pressure kick or timer?

Wes

[Jason Tuinstra]

Jim, great job! Anyone would love to have that setup. BTW, how were my birthday brownies? :D :p

[Chris Padilla]

Jim,

Looks good...I sweated enough copper while crawling around under my house that I have no wish to repeat it...unless I'm comfortably in my garage! :D

I have a question, however, and that is with regards to condensation in your lines. I notice you have the main line filtered but is that enought to keep water out of your lines throughout the shop?

I was always told to put in compressed air lines with the thought of water dripping in mind and to put points where it would collect so that you could easily remove it by opening a valve here and there.

[Bill Lewis]

Jim,

I actually don't mind sweating copper. In alot of ways I prefer it to working with pvc. Dry fitting for instance, is better with copper. I did buy a new torch head with the push button on/off. It works great while working one handed in tight spaces. Not that I would use pvc, or cpvc for air any way. I too used copper for my air system.

Actually that's not why I am responding. I just wanted to throw another vote in for Flexeel hose. I first saw the hose on a TOH episode and thought that it looked primising, but I never saw it come to the market. The first time I got to see it "in the flesh" was severral years ago during the construction of my house. A group of framers were using it. I was impressed with it, but I couldn't find a convienent local supplier, nor a good online supplier.

So, as of now, I still don't have any. However, since you brought it up, I just did another search and I found another supplier in addiiton to the one listed on your website (Coastal (http://www.coastaltool.com/cgi-bin/SoftCart.exe/a/ab/coilhose/flexeel.htm?E+coastest)).

Tools-Plus (http://www.tools-plus.com/coi-compressor-accessories-hoses--reels----parts.html) sells both the hoses and more importantly, they also sell the end fittings. I was mostly concerned with the availability of the fittings before buying the hose. Plus, I could only find online suppliers that only sold it in 100' lengths. Now I can also buy some 100' lengths and make custom lengths with the end fittings.

[Rick Lizek]

I do lot with commercial air systems and the prefered way to do a drop is to have the pipe go up from the T or elbow, then it drops down. See the pic with the green coil hose and the last pic in the series. That way the main water goes down the pitched pipe and won't collect in the drops. Typically on a small system the main pipe would be pitched to the compressoer tank to utilize the drain in the tank. Also on the actual drop it's recommended to extend the pipe down with a drain valve so the water can't accumulate. I'm referring to the pic with the filter for you spray filter. The bottom disconnect is at risk to spray water through a tool or whatever.

[Sam Blasco]

jim, that looks way too neat and tidy for a woodshop. looks like valuable time was spent (wasted some might say) that could have been used making shavings for a cradle or rocking horse. ;}.. really, nice job.

[Corey Hallagan]

Wow, that is a pretty cool set up. Nice work!

Corey

[Jim Becker]

jim, that looks way too neat and tidy for a woodshop. looks like valuable time was spent (wasted some might say) that could have been used making shavings for a cradle or rocking horse. ;}.. really, nice job.

LOL! Cradle...no. One would hope that a 4 year old and a 5 and a half year old wouldn't need one. But a rocking horse is a nice idea...after the toy box, however.

On a more serious note, I do try to keep the shop reasonably clean for both safety reasons and because I like it that way. It's a good habit to get into...clean up at the end of the day or at least the end of the weekend. 'Less to deal with later and easier to find things. Oh, and I'm anal...:o

[Jim Becker]

I do lot with commercial air systems and the prefered way to do a drop is to have the pipe go up from the T or elbow, then it drops down. See the pic with the green coil hose and the last pic in the series. That way the main water goes down the pitched pipe and won't collect in the drops. Typically on a small system the main pipe would be pitched to the compressoer tank to utilize the drain in the tank. Also on the actual drop it's recommended to extend the pipe down with a drain valve so the water can't accumulate. I'm referring to the pic with the filter for you spray filter. The bottom disconnect is at risk to spray water through a tool or whatever.

I agree with everything you said, Rick, and originally planned to do it that way. But after mulling it over for a long time (really!), I decided to just manually drain any condensation in the drops from time to time since this isn't a commercial shop and I didn't have any more patience to sweat more pipe or put more money into it. I just wanted more convenience.

[Rick Lizek]

Nice job, Jim I used 3/4" sch40 pvc in my last shop worked great. I haven't done it yet in this shop but I do miss having not to trip over the hoses on the floor.
If you want the convenience of plastic air lines only ABS is rated for air lines. PVC is dangerous and not OSHA approved. You may have had good luck but there are many documented cases of others less fortunate.
Chem-aire is air line rated http://www.nibco.com/cms.do?id=2&pId=14

[Rich Konopka]

Great Job Jim.

Did you have to use a certain copper pipe grade?

[Jim Becker]

Did you have to use a certain copper pipe grade?

I used Type L copper.