John, I also started with a 2 HP bag collector many years ago and used 4 inch S & D pipe. In my new shop that I just finished setting up I now have a 3 HP Grizzly cyclone. Other than the metal reducer I used right at the inlet the rest of the system is mainly 6 inch and some 4 inch PVC. I'm in Lapeer County, MI and bought my 6 inch S & D fittings from Menards when they have one of their 11% off sales. They have the best price for the fittings, but not the pipe. Find a cement company that also sells excavation material. They are generally the cheapest for the pipe, but charge much more for the fittings. The best blast gates on the market are the self cleaning ones like Lee Valley sells. Turns out that a company here in Warren, MI makes them for LV, and they are a little cheaper. Check them out at blastgateco.com. They also sell a lot of various grade flex hose at reasonable prices.
As far as one poster mentioned the issue of static buildup is a very debatable issue. I was concerned when I started out many years ago, but research indicates that static charge buildup from wood dust is only a possibility in larger, industrial systems. And since most of those systems use metal pipe it is not an issue. For us hobbyists with our smaller systems it is not a problem if we use PVC pipe.