Thanks Wiz. Ok, you got me I'm going have to look up a "Thein type" cyclone!
I've thought and still am thinking about a sight glass or something but you can't believe what a mess it is inside that bucket. It's all black (that's the main color I use) and it literally coats the inside of the bucket. It's worse than when it went straight into the vac. So I'm thinking I'm not going to see through a sight glass setup. Dunno. I also forgot that it's really easy just to unplug the hose from the top vac hose and look into the white PVC elbow. If there's any black dust there....it's time. It is a bit of a hassle to pull the top of the bucket with the "razor pig tower" attached. But whatchagonnado? Depending on how many runs of powdercoat I do it could be a month, sometimes two before I have to empty it.
Wow, your buddy doesn't want much, eh? My rig I've also used for my HFT sandblast cab and it works great. Keeps the air clear in the cab so you can see what you are doing and not even a hint of that totally nasty dust in the shop. But 12v and no filter? You crack that nut Wiz, I wanna see!

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