This project was built and designed by Danny from ModernRemade. It’s a mobile dust collection cart with a built-in cyclone separator, designed to keep your workshop clean, organized, and more efficient.
Danny’s build combines clever design with real workshop needs—dust control, tool storage, and easy mobility. If your shop struggles with clutter or sawdust buildup, this compact solution could make a big difference.
Watch the full video and subscribe to Danny’s channel:
Why Dust Collection Matters
Dust is more than just a nuisance—it’s a hazard to your health and your workflow. As Danny points out, sawdust can feel like nails on a chalkboard when it gets into the wrong places. It clings to everything, affects your tools, and can even become a fire risk if not managed properly.
Installing a reliable dust collection system helps prevent these problems before they start. For small to medium workshops, a cart-based system offers flexibility without needing dedicated ducting or wall-mounted systems.
Sketching Out the Design
Danny began the project with a rough sketch and refined the concept using SketchUp. This helped him visualize how each component would fit together and ensured he could size everything around his existing shop vac and cyclone separator.
A key part of the design is its modularity. The cart is built to be customized, with space-saving ideas and simple joinery techniques that make it beginner-friendly.
Cutting the Materials
Since transporting full sheets of plywood isn’t always feasible, Danny recommends cutting them down for easier handling. Using a straightedge guide with a circular saw, he accurately sized all panels before bringing them into the shop.
By pre-cutting all pieces and labeling them, Danny minimized confusion during assembly. This prep work allowed the build to move smoothly once the parts were ready.
Assembly with Pocket Holes
Using pocket holes, wood glue, and clamps, the main cart structure came together. Danny emphasized the importance of double-checking pocket hole placement, as misaligned joints can quickly throw off the rest of the build.
Clamping during glue-up was done carefully to avoid warping panels. A methodical approach helped ensure the structure stayed square and sturdy.
Smart Dust Bucket Access
One standout feature of this cart is its easy-access dust collection bucket. Danny designed a housing that fits the bucket snugly but allows for quick removal when it’s time to empty it.
To keep the bucket in place without complicated hardware, he used magnets and spring clips—making the system both secure and user-friendly. This small innovation turned out to be one of the most helpful aspects of the entire build.
Improving Suction with a Cyclone Separator
With everything assembled, Danny tested the system’s performance. The combination of a shop vac and a cyclone separator significantly boosted suction, collecting even fine dust before it reached the filter.
This not only improved shop cleanliness but also extended the life of the vacuum and reduced the frequency of filter cleaning or replacement.
Modular Tool Storage with French Cleats
On the side of the cart, Danny installed a French cleat wall. This allows for adjustable, removable tool holders that can be rearranged as needs change.
He built custom holders for common tools and supplies, keeping them visible and accessible. French cleats also add flexibility—making this cart adaptable for future projects or upgrades.
Extra Features for Convenience
Danny didn’t stop with basic functionality. He added a magnetic bar for holding metal tools, a cradle for extension cords, and a bin for shop rags. These simple additions help reduce clutter and streamline daily tasks.
Another practical feature is the automatic vacuum switch. When a connected power tool starts, the vacuum automatically turns on—and shuts off shortly after the tool stops. This eliminates the need to manually switch the vacuum every time you make a cut.
Overcoming Build Challenges
Like most shop builds, this one came with a few hiccups. Danny faced minor issues with alignment and cart balance early in assembly but made adjustments along the way.
Learning how to deal with unexpected obstacles is part of every woodworking project. Danny’s approach—slowing down, making corrections, and adapting the plan—reflects real-world shop experience and encourages others not to get discouraged when things go off script.
A Compact Workshop Upgrade
The completed dust collection cart is not just a cleaner solution—it’s also more efficient. With tool storage, easy-empty dust disposal, and improved suction all packed into one mobile unit, it solves multiple problems at once.
Danny’s design balances practicality with thoughtful touches that make it easy to use daily. Whether you’re working in a garage, basement, or dedicated workshop, this cart can help you reclaim your space and breathe a little easier.
Watch the full video and subscribe to Danny’s channel: