This project was built and designed by Mark from Gunflint Designs. It’s a practical reimagining of a traditional dust collection system—built around a shop vac and Dust Deputy—but without the clunky 5-gallon bucket.
Mark’s goal was simple: make dust collection easier to manage, more efficient in tight spaces, and cleaner to maintain. His redesigned cart system solves the usual problems by focusing on smart layout, sealed containment, and improved access to the dust bin.
Watch the full video and subscribe to Mark’s channel:
Rethinking the Typical Dust Collection Setup
Most small-shop dust collection setups use a 5-gallon bucket with a cyclone separator mounted on top. While it’s an effective system, it’s also awkward. Removing the lid to empty the dust can be frustrating, especially when suction pressure has sealed it shut or the contents spill while trying to lift the heavy bucket.
Mark approached the problem from a usability standpoint. Rather than accepting the hassle as part of shop life, he designed a pull-out bin system that’s easier to access, empty, and reseal. This change alone removes one of the biggest pain points of dust collection: cleanup.
A Smaller, Smarter Footprint
Another issue with traditional carts is how much space they take up. Many shop vac and cyclone setups are wide, cumbersome, and not easy to tuck away when not in use. Mark addressed this by designing his cart with a vertical orientation.
By going vertical, the system conserves horizontal space and fits more naturally along walls or between tools. For smaller shops—especially garages or shared workspaces—this change is a game-changer. Elevating the bin and compacting the footprint without sacrificing function makes the cart far more practical.
Upgrading Dust Containment
A key issue with bucket-based systems is dust escaping around the lid. Over time, this adds more cleanup and allows fine dust to circulate in the air. Mark’s cart improves containment by adding a foam gasket around the rim of the dust bin.
This foam creates a tighter seal, reducing gaps and keeping fine particles where they belong—in the bin. The result is a cleaner work area and less airborne dust. It also means fewer cleaning sessions after dumping out collected material.
Materials and Construction
Mark builds the cart with durability in mind. Using plywood and available scrap wood, he constructs a strong frame that holds the shop vac and Dust Deputy securely. The bin fits snugly into a custom compartment, guided by rails or slots that allow it to slide in and out easily.
There’s also thought given to accessibility. The hose, power cord, and switch are all kept within easy reach, minimizing setup time. Every part of the build is designed for convenience, showing how smart planning can elevate a simple project.
Testing and Refinement
Once assembled, the cart is tested for airflow and functionality. Mark finds that dust is effectively captured and contained with minimal leakage. The cyclone still separates large debris efficiently, protecting the shop vac’s filter from clogging.
Like any project, there’s room to improve. Mark makes small tweaks to the balance of the cart and adds minor reinforcements where needed. He’s open about what worked immediately and what required adjustment, making this project approachable for others looking to replicate or adapt it.
Why It’s Worth Doing
Dust collection is one of the most overlooked shop systems, yet it’s critical for maintaining a healthy and efficient workspace. Mark’s project shows that you don’t have to spend a fortune to build something effective—and you don’t need to settle for the frustrations that come with off-the-shelf setups.
By eliminating the 5-gallon bucket, he’s improved both the workflow and the cleanup process. Emptying the bin is no longer a chore, and the sealed design means less dust escapes back into the shop.
Practical Improvements, Real Results
Every aspect of this build reflects real-world workshop needs. It’s sturdy, space-saving, and easy to use. Best of all, it’s adaptable—woodworkers can scale the design up or down based on their own shop size or tools.
Mark’s cart isn’t just functional; it’s a great example of workshop problem-solving. It takes a standard idea and improves it in multiple ways, from usability to cleanliness.
Watch the full video and subscribe to Mark’s channel:
(Embed YouTube video here)
You can see all of Mark’s plans here: https://www.gunflintdesigns.com/project-plans.