This project was built and designed by Jay Bates. It’s a simple but effective solution for managing dust collection in the workshop, using 4-inch PVC and plywood to create reliable blast gates at a fraction of the cost of store-bought options.
With clear steps and a smart design, Jay’s approach to building custom blast gates is easy to follow and highly adaptable to any woodworking shop. If you’re looking for a budget-friendly upgrade that actually improves workflow, this project is a great place to start.
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Why Blast Gates Matter in a Workshop
Blast gates help control airflow in a dust collection system by isolating suction to the tool you’re using. This prevents the system from being overworked and keeps the shop cleaner by improving suction where it’s needed most.
Jay shows how to make these gates from materials that are commonly available, and the result is a customized setup that’s more efficient and durable than many off-the-shelf options.
Materials and Components Overview
The build centers around 4-inch PVC pipe and couplings, along with sheets of plywood and some scrap wood for handles. Construction adhesive is used to form strong, permanent bonds between the materials.
You’ll need:
- 4″ PVC couplings
- 4″ PVC pipe
- Plywood panels
- Scrap wood for gate handles
- Construction adhesive or epoxy
- Basic shop tools (table saw, drill, router, etc.)
This project doesn’t rely on exact dimensions, which makes it easier to adapt to your own setup. Jay focuses on method and function rather than strict measurements, allowing more flexibility during the build.
Cutting and Prepping the PVC
The process starts with cutting the PVC pipe and couplings. Jay uses a table saw to get clean, accurate cuts across the pipe, which helps the components seat properly during assembly.
To improve glue adhesion, he scuffs the edges of the PVC using sandpaper. This is a small step that makes a big difference in how well the adhesive bonds to the surface later.
Plywood Layout and Marking
Once the PVC is prepped, attention turns to the plywood. This will form the body of the blast gate. Openings are marked out where the PVC couplings will pass through, and the layout is repeated for multiple gates to streamline the process.
Accuracy during this phase is important for achieving a tight seal. A clean fit between the PVC and the plywood reduces the risk of dust leakage, which helps maintain strong airflow in the system.
Drilling and Assembly
A drill is used to rough out the openings for the PVC. Jay removes just enough material to fit the couplings into place while still allowing for a snug fit. Once the holes are cleared, the components are dry-fit and adjusted before applying any adhesive.
Construction adhesive is used to bond the PVC to the plywood. It’s applied generously, and the pieces are clamped or weighted until fully cured. This step gives the gate its long-term strength and ensures the system will hold up under frequent use.
Routing and Cleanup
Once the adhesive has dried, Jay uses a flush trim bit in a router to clean up the plywood edges around the PVC. This creates a smooth, professional finish that ensures the gate sits flush when mounted to the system.
He also rounds over the edges of the plywood slightly, removing any sharp corners and improving handling when the gate is opened or closed.
Improving Gate Functionality
To make the blast gate even more effective, Jay adds a simple flap made from painter’s tape. This flexible seal closes off the airflow tightly when the gate is closed but still allows small chips or dust to escape when the gate opens again.
It’s a small addition, but it greatly improves the gate’s performance—especially for tools that produce larger debris.
Why DIY Blast Gates Are Worth It
Store-bought blast gates can be expensive, and they often don’t fit perfectly in custom systems. By making your own, you can tailor the design to your exact tool layout, improve sealing, and save money in the process.
This project is also a good opportunity to practice essential woodworking skills like layout, precision cutting, and assembly techniques—all while creating something useful for your shop.
A Smart Upgrade for Any Workshop
Jay’s 4-inch PVC blast gates are a great example of how practical woodworking can solve real shop problems. With just a few basic materials and tools, you can build a dust collection upgrade that works better than many commercial options.
For those managing a multi-tool dust collection setup, installing a few of these custom gates can make a noticeable difference in shop cleanliness and system performance.
Please support Jay by purchasing his plans here: Jay’s Custom Creations.