Woody, I haven't had time to follow the whole thread. Did you check to make sure there was no leak in the bin? I suspect you did. If you have someone release a big handful or small container of sawdust and shavings into the open end of a duct while watching the cyclone (with good lighting) there should be a distinct spiral of the dust around the outside, the sawdust gradually descending until still spiraling, it falls into the bin.
I'd use a mix of fines and large shavings but a mix of shredded paper, cardboard, grass trimmings, floor sweepings, etc should also work. (Just don't vacuum up any cat litter like I did once unless you want to cloud the inside surface of the ClearVue cone!) If there is a serious leak in the bin all the sawdust might not make it to the bin but be pulled off the cone somewhere in the middle of the spiral and pulled up into the central tube and passed to the filters. If there is a minor leak this might not be so obvious. If the cyclone is working correctly even talcum-power fine dust will be deposited into the bin. There should be almost nothing coming out of the exhaust towards and into the filters. After 6 years of use I see only a tablespoon or so of fine dust in the cleanout box below my filters. You could disconnect the filters while doing this just in case so any dust sent that way doesn't make it into the filters. Maybe hold a cloth bag on the end to collect anything that might come through.
If you've already tried this, then nevermind!
A thought: Another test might give you an idea of the relative amount of suction between your cyclone and one that is remote, like mine. Cut a small piece of thin plywood/hardboard,plexiiglas etc that will cover the end of your duct, maybe at least 6" square so it could be used on a vertical 6" duct as part of the test. Perhaps screw a cup hook into the middle of one side and let it be pulled tightly against the end of the duct. (The duct should be smooth or have a PVC connector on the end so it seals well.) Hang a increasing amount of weight on the hook until the suction will no longer hold the plywood and weight. I'd try this with both the 4" duct and the 6" duct to see any difference, horizontally if necessary but seems a vertical duct would be better. Report findings and I and/or someone else will repeat it with their system. If there is a big difference in suction it should be obvious. If the difference is small you can go on with your life.
You might do this with and without the filters attached to qualify that varible.
Mine has a 5hp motor and a 15" impeller, 6" PVC ducts.
If you choose to do this be sure to restate your system specs along with the results.
JKJ
Originally Posted by John K Jordan
A thought: Another test might give you an idea of the relative amount of suction between your cyclone and one that is remote, like mine. Cut a small piece of thin plywood/hardboard,plexiiglas etc that will cover the end of your duct, maybe at least 6" square so it could be used on a vertical 6" duct as part of the test. Perhaps screw a cup hook into the middle of one side and let it be pulled tightly against the end of the duct. (The duct should be smooth or have a PVC connector on the end so it seals well.) Hang a increasing amount of weight on the hook until the suction will no longer hold the plywood and weight. I'd try this with both the 4" duct and the 6" duct to see any difference, horizontally if necessary but seems a vertical duct would be better. Report findings and I and/or someone else will repeat it with their system. If there is a big difference in suction it should be obvious. If the difference is small you can go on with your life.
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(Just kidding, but I've in fact had something very similar happen to me, and you've seen the video.)
