1a - Marking the circumference

1b - Sawing cutout

Directions: 

Step 1 - Setting up the fan support board:

Using the 3/4" piece of plywood, locate the center of the board.

Place the gable fan over the center point and trace the outside circumference.  (Photo 1a)

TIP: use a dull pencil for thicker line.

Drill 1/2" pilot hole inside the circumference line.

Using saber saw, cut out the fan opening. (Photo 1b)

TIP:  Saw just outside circumference line.

Test fit fan into cutout. (Photo 1c)  Do not install fan at this time.

2a-Heat Switch

Step 2 - Setting Up Fan Motor:

Using flat screw driver, remove cover from heat switch (Photo 2a) and disconnect the wires. (Photo 2b)

Using a pair of pliers, gently squeeze the box connector "snap flanges" and remove from electrical box.  Save the wire nut, discard heat switch and electrical box.

3a-Marking 3" lines

3b-Install filter rests

3c-Fan from Home  Depot

Step 3 - Assembling Dust Box:

Measure 3" in from the back and front edge and draw a line on the top, bottom and side pieces. (Photo 3a)

Line up the fan support board inside the back 3" line and attach sides, top and bottom with dry wall screws.  Apply glue around support board edges to strengthen joint.

Measure from the support board to the front 3" line and cut four 1 x 2" pieces to fit.  (4 pieces of equal length).

Glue and fit the cut pieces into the inside corners, continue to screw the top, bottom and sides together from outside the box, driving screws into the corner blocks.

Measure the distance between the corner blocks (inside to inside) and cut the 1 x 2 " pieces to fit top, bottom, and sides.  Cut to fit tightly. (Photo 3b) Do not install at this time.

Install fan into box.  Decide which side of dust box you want to install the on/off switch and rotate fan so that wires from fan motor will easily reach that side.  If you bought the fan pictured from Home Depot, (Photo 3c) you will find four screw holes in the fan shroud.  Center these holes on the 3/4" support board and screw the fan into place using dry wall screws.               

TIP:  Spin the fan blade by hand, making sure the blades turn freely.

With the fan motor installed, glue and screw the cut 1 x 2" pieces into place, from outside of box.  This forms the inside filter rest. (Photo 3d)

 

4a-Drill hole for wires

4b-Connect wires to switch box

Step 4 - Installing On/Off Switch:

Locate where you want to install the on/off switch and drill a    1-1/8" hole. (Photo 4a)

Feed motor wires through the 1-1/8" hole and attach the wires to the back of the electrical box using the existing connector.    (Photo 4b)

Using sheet metal screws, attach switch box to dust collector.

Make sure the electrical cord is unplugged! 

Connect the white wires together with the saved wire nut.  Connect the black wires to the switch - not on the same screw! (Photo 4c)

Using a sheet metal screw, attach the green ground wire to the box.

Install switch cover plate.

After checking to make sure the blades are clear and

 unobstructed, and the switch is in the OFF position, plug in the electrical cord.  Turn switch to ON position and test run fan.

5a-Filters

5b-Fitting the filter stays

5c-Finished Dust Collector Box

 

Step 5 - Installing Filters:

Measure and cut two pieces of 1 x 2" to fit along the sides.  These pieces need to be cut so that they have to be pressed in to fit.   

Place filters into box and install the side pieces to hold filter in.

Measure and cut two pieces of 1 x 2" to fit the top and bottom along the front of the filter.  Again, these pieces need to be cut so that they are pressed in to fit.

 

This completes the assembly - go carve a decoy!