27 Photos - Apr 6, 2009
Photo: I have wanted to build a waterfall style spray booth for a long time.  I saw my first one at the Red Star Studios in Kansas City that Jesse Hull had built.  Recently someone posted a link to Tom Turner’s design (shown above) on his web site.  The unique feature of Tom’s design is the use of a three piece shower stall as the framework for the booth.

I went to my local building supply store to start Tom’s version of the project and discovered two things.  The first was the cost of a shower stall was about $350.  I’m cheap and that seemed like a lot of money just to start the project.  The second was the size.  It was much larger than I expected and bigger than I needed.  I asked the salesperson if they had any seconds.  He said they didn’t but if I wanted to make a less expensive, smaller version I should just get a 50 gallon plastic drum from the wholesale food supplier down the street.  So for $15 I got started.Photo: This is a fifty gallon plastic drum from a wholesale food supplier.  This one had residue of organic molasses in it which had to be hosed out.Photo: I drilled four holes at the corners of the cutout then I cut it out with a jig saw.  I left 3 inches on the top and bottom.  The opening is about 22”w by 28”h.Photo: I installed the cut out piece close to the top as the false wall.  It is attached to the back with 2 inch 1/4x20 stainless steel bolts sealed with rubber washers.  This is where the water will flow and wash the glaze down through the drain.  The drain is a standard kitchen sink drain.  There is 1/2” PVC pipe behind the false wall.Photo: Detail of the sink drain and lower part of the 1/2” pipePhoto: Detail of spacer to keep the false wall away from the back wall.  It is a 1 inch long piece of the 1/2” PVC pipe.Photo: This sprayer (version 1) is made of 1/2” pipe and 45° connectors.  Small holes are drilled along the backside (see detail next)Photo: The holes are drilled at an angle so the water hits the back wallPhoto: Sprayer in place.Photo: 4 1/2 inch hole in the back wall for the exhaust fan.  I had to push the pipe out of the way before I drilled the hole.  This will pull air through the booth.  Eventually there will be a structure to hold a filter.  But for now…..Photo: Exhaust fan attached to back of booth.Photo: A larger view of the back.Photo: A full view of the front.Photo: Sump pump and hose to feed water to the sprayer.Photo: This is the pump I usedPhoto: Water connection from pump to pipe to sprayer.  I routed the pipe up through the middle of the drain.Photo: Sprayer assembly version 2.  This uses sprinkler heads to disperse the water.Photo: Detail of sprinkler head sprayer assembly.Photo: Sprayers in actionPhoto: Here is the latest additions to my spray booth. The waterfall was working fine but the fan was not strong enough to exhaust the mist. So off to my friends at the Harbor. Now it works.Photo: And there was some splash so I added some foam.Photo: 2-1/2 HP, 10 Gallon, 125 PSI Air Compressor ~$150
	Air delivery: 5.3 SCFM @ 90 PSI
	6.2 SCFM @ 40 PS I1/4"-18 NPT
	Easy-to-carry handle and smooth-rolling wheels for hassle-free mobility
	Direct drive induction motor with thermal overload protection
	Clear view oil window lets you know when its time to refill oil
	High impact ABS shroud for maximum protection
	Easy-to-read pressure/regulator gauges indicate CFM and PSI
120 volts, 14.1 amps 60 Hz
3400 RPM 125 PSI max working pressure
Air delivery: 5.3 SCFM @ 90 PSI
Cord length 6 ft.
Overall dimensions: 36''L X 22-1/4''W X 13-1/4''HPhoto: 20 Oz. High Volume Low Pressure Gravity Feed Spray Gun (Need 3) ~$15x3
High volume, low pressure for high output with lower overspray. Better for the environment, helps you save money on material costs.
	Best mix of paint and air pressure
	Uses most oil based paints
	Adjustable fan pattern and volume control
	Includes cleaning kit, wrench and barbed inlet fitting
Required air supply: 1-3 HP compressor
Required air pressure: 50-70 PSI
Air consumption: 6 CFM Air inlet: 1/4"-18 NPS
Output: 200-300 ccs per minute
Cup capacity: 20 oz  Nozzle size: 1.5mmPhoto: Quick-Change Airbrush Kit  ~$10
Switch glaze colors in seconds.
	No need to clean gun between color changes
	Adjustable paint flow and spray patterns
	Chrome-plated brass nozzlePhoto: 3-Way Quick Coupling Manifold  ~$10
This coupling manifold is designed to simplify multiple tool operations.
	1/4" industrial standard coupler with 3/8" inlet
	Allows three work stations to use the same air supply
	Durable aluminum and brass construction
1/4" NPT air outlet 3/8" inletPhoto: ~$20
25 ft. x 3/8" Heavy Duty Black Rubber Air HosePhoto: ~$5 (Need 3) 
1/4" x 25 Ft. Self-Coiling Air Hose.