Started a replacement for my shop vac dust separator yesterday.   I cold not sift through 50 pages of topic headings and multiple posts per thread, so I just used Phil Thien's original directions.    Had to replace the lid on my Rockler Vortex separator that cracked.   Will keep you posted on progress.

Made from salvaged plywood, leftover dowel shorts, and connectors from the original top.

Next up is a similar set up for my 30 gal garbage can and 4" dust collector hose.

 

Glue up

 

Overall photos

 

In action 

Did you cut those parts with a router/trammel?

Watched this video the other day.  Has some good points in it.

 

 

How are you attaching the top to the barrel?

2 hours ago, Woodbutcherbynight said:

How are you attaching the top to the barrel?

Friction fit.   I had 3/8" plywood that I didn't think would be quite stiff enough so the top piece is routed out to fit over the lip of the bucket and I cut a second piece that fits right inside the top.  You can see this in some of the close up photos.  The two are glued and screwed together.  I was planning to use some door gasket, but found I didn't need it.  The extra wide lip (1" or so) gives me a place to grip to pull it off to empty contents.

Fred, yes, router with a 1/4" mortising bit.  You can see it in the photo following the "Glue up" -- it's just a piece of plywood that I screwed the router base to then drilled pivot holes where needed.