As part of the research, I came across:
Because the person (Ed Morgano) making the ClearVueCyclones lived close to my parents in SC which I was visiting from Chicago over TGiving I decided to pay him a visit. Ed is a really nice guy and cares alot about the precision and quality of what he is making. I got to see his clear cyclone in action. He had it connected to a 0.5 micron cartridge filter. When I put my nose up to the cartridge filter I could not even smell wood dust.
Additionally this cyclone is designed after a design by Bill P. (above). It transitions from round to square prior to the dust collector and then enter the cyclone tangential at about 15 degrees off horizontally and pointing downward which matches the swirl in the collector. Since he is using clear material for the collector and exit from the top mounted blower you can see (or not see) the dust in the air exiting the cyclone. I could not see anything exiting the cyclone.
Ed M. which owns clearvuecyclones.com is running basically a 2 man shop building these.
I am also a registered mechanical engineer about 5 years out from retirement. I feel this is the best system money can buy and if you read Bill P.'s (also engineer) site you will see he has done a tremendous amount of trial and error testing to come up with his data.
I have now ordered the clear cyclone, 170 feet of 6" S&D PVC, and a bunch of wyes, 45's, and 90's and will be connecting Unisaw, DJ20, Delta Stationary 15" Planer, 12" Dewalt compound, Delta Var. Lathe, Delta 14" Bandsaw, Powermatic Shaper, Mortiser, Delta Jigsaw, Delta 12x48 sander, downdraft table, Powermatic Oscil. Sander, 3hpPC router table.
I will be removing the motor and blower from my DC1900 and mounting on the cyclone.
I just hope I don't die, get layed off, or get transferred since this dust collection system will be quite a bit of work and it will be the first time my shop will be fully integrated together.
This is my Christmas Present.
Check out the ClearVueCyclones, it might be your Christmas Present too.