The Electrostatic Precipitator Tube Assembly

To begin first get five 10ft length galvanized steel 2" round gutter down spouts. Cut these pipes into five 2ft sections using a hacksaw. It is helpful to mark a guide line by wrapping a piece of paper around the tube and tracing the edge of the paper with a marker.

Once you have cut all 5 pipes to get a total of 25 pipe segments, drill four 1/8" holes on both ends of the pipe in a cross pattern so a small zip tie can fit through the holes. The holes are about 1/4" from the edge of the pipe.

Now get a 10ft length of 1 1/4" PVC pipe and cut 35 (thirty-five) 2.5" to 3" segments.

On each PVC pipe segment, drill four 1/8" holes on each end in a cross

pattern. The holes are about 1/4" from the edge of the pipe.

Now each metal pipe and PVC pipe should have holes on their ends that roughly match each other.

Now run 4 zip ties through the metal pipe and into the PVC pipe section to zip tie the pipe to the center of the metal pipe.

For the other end of the pipe, route two zip ties into the holes and connect the zip ties together.

Do this for all of the pipes.

Now route 24 gauge steel wire from the PVC end and tie it to the two zip ties at the other end. NOTE THAT YOU MAY WANT TO WIRE THE TUBES AFTER YOU ASSEMBLE THEM TOGETHER IN A BUNDLE! THIS WILL SAVE MUCH MORE TIME.

Take a shish kabob skewer and run it though the other end of the PVC pipe and wrap the other end of the wire to this.

Then tighten the wire by wrapping it around the wooden skewer and turning the shish kabob skewer so the wire is taught in the center of the tube.

Once this is done for all the pipes, it can be assembled into one large parallel block.

Get two rectangular or square buckets with lids. Do a dry fit to make sure all 25 pipes can fit inside.

Take both of the bucket lids and drill 25 2" holes in them so the pipes can be routed through.

Try to do this without destroying the lid. If the lid is destroyed, wood can be used.

Now route a layer of pipes through the plastic lids and seal the lid to the pipe using silicon caulk.

I ended up destroying the lids in this process. Now I will show you how to do this with wood.

Layout the 25 2" holes in a grid on two pieces of boards and drill the holes out.

Drill all of the outer holes so the center piece of wood is left. The central piece of wood is cut so the star pieces of wood can be used to fill the gaps between the tubes.Route a layer of pipes through the two pieces of wood.