Hi Dustin, some ideas for you:
1. New Shop - Go to Highland Woodworking's site they have a gallery of shops to look at.
2. The 4 inch green thin walled S & D pipe is a bell end pipe, but the non-belled end fits standard DC fittings.
3. I'm looking to buy a dust collector and have nothing but good reports on Harbor Fright's 2 hp. DC.
4. Ducting size - I feel 6 in. pipe in a small shop is over kill. I have seen a commercial shop running 3 in.with a very powerful DC and it worked. For myself I will use 4 in. Just my ideas.
Pop
I used to think the same thing. From my experience I assure you 6" pipe is not overkill.
During a recent remodel, I demo'd my entire DC system and started from scratch. The old system was the 4" S&D pipe.
I did several things:
--Repiped in 6" with 4" drops. My shop is not big -- the longest run is about 20'.
--Kept my high producers closest (drum sander/plane/jointer)
--Incorporated a cyclone.
--Dismantled blower from mobile base and installed in a frame directly above cyclone.
--Got rid of the bag and vented outside.
The combination greatly reduced resistance and gave me a huge boost in performance, and this is with a 1 1/2HP 1100 CFM unit.
I was planning on getting a bigger blower, but I gave the old one a try and it works fine.
As far as HF, I've heard people say they are OK, but I would caution you to research blowers a little. There are big differences in steel vs. aluminum and from what I've read, the advertised CFM's are often overrated.
CFM and air speed are greatly affected by duct size don't limit your blowers capability with small ducting.
I've been in commercial shops with DC's that violated alot of rules about DC, so it doesn't make it right!