I made the baffle myself. I scaled Phil Thien’s design to fit the 5-gallon bucket.

I wrote an article on how I did it, complete with all the measurements. http://www.evenfallstudios.com/woodworks/2008/06/27/building-the-5_gallon-thien-separator/

I now use a 7-gallon bucket with my separator. It works even better for both separation and capacity. My separator has passed the extreme use test. I am a full time woodworker and toolmaker, so my separator sees commercial use daily. It is attached to sanders, routers, router tables, chop saw hoods, and my drill press, as well as all my general vac attachments. It handles chips from hand tools and power tools. It has exceeded my expectations, and has seen an enormous amount of sawdust.

Harbor Freight has the best price on the bucket lids, I’d get them there. It is the same lid Woodcraft sells, but for less than half the price. I highly recommend building the baffle, adding it to the Harbor Freight lid. Remember to make the lid modification by drilling the hole in the center of the lid, and mounting the suction port there, then block the unused port, as that is also key to the design. Then google for a 7-gallon bucket. You’ll be pleased.

Bests,

Rob

The baffle modification to the (2) Woodcraft parts (143868, 85013)…did you build that, or purchase it?

JOEY