OK, I have an interim report on the 5-micron pore size polyester felt filter "paper" (more like upholstery fabric) I purchased from McMaster-Carr. It's a densely-fibered white felt, about 1/16" thick. For $20, I bought a 3' by 6' roll (the smallest amount that can be ordered). This should be enough to last me forever, given that the felt is reusable (a fact I can now confirm---after filtering a tobacco maceration, the felt washes out easily and apparently completely just by holding it under a strong stream of running water in the kitchen sink; the white color does darken to a light tan after filtering, so some residue must remain, but one 3" cut-out felt circle worked fine today to filter four macerations, with easy rinses between each).
I was concerned that the felt might not work in my French Press coffee pots, fearing that the circular felt wouldn't seal against the inside of the cylindrical glass (Melior) or plastic (Bodum)pots, allowing liquid to bypass the filter around the side as the plunger was pressed. This concern motivated me to research hand-vacuum filter kits online, which sell for $40-150 depending on size and vendor. I read tons of reviews on Amazon and elsewhere, and the negative reviews were always the same: cheap plastic hand-operated vacuum pumps were invariably the problem. Either they didn't work well, or they were flimsy and broke. All the kits on Amazon or eBay or school lab equipment sites seems to use these cheap plastic Chinese hand vacuum pumps.
I decided to put together my own "kit" from separate parts: 500ml Ehrlenmeyer borosilicate filter flask, 70mm Buchner ceramic funnel, and a Mityvac MV8510 Silverline Elite Hand Pump (far and away the most dependable, well-made, heavy-duty, all-metal hand vacuum pump available, even if it is made for automotive use on brake lines), plus hose and stopper. That kit would set me back around $150 total. I wasn't thrilled, however, about the prospect of spending that much on filtering equipment. Heck, that's more than I've spent in total for my 27 previous extractions.
Well, it turns out that I need not have worried. The 5µ poly felt filter works beautifully with my 3-cup, 12 oz. Bodum small French Press, which is the perfect size for the tobacco extractions I do. My big Melior French Press would work also, but the small Bodum is a better size, because it lets me press the tobacco solids to release most of the absorbed PG/VG.
This was my 9th batch of extractions---four different pipe tobaccos, three from the Hearth & Home Signature Series (Freight Train, Steamroller, and Stogie), and one from Milan (Chartwell, an English blend). I altered my pipe tobacco "formula" for these macerations, using 1 oz. of tobacco rather than half an ounce, covered with 125-150ml of 65PG/35VG, the amount of liquid depending on the volume needed to cover each tobacco, which varied from one to another. The sealed-jar macerations spent 24 hours in a warm water bath inside my large pasta pot, with the water temperature as controlled as I can make it using one of the 50-year-old Jenn-Air old-style electric-coil burners in my apartment's kitchen. I get a very nice 130° with the control set to "Lo" and the lid off the pasta pot. All I have to do over the 24 hours is top up the water in the pot from time to time, since it evaporates slowly.
I filtered the macerations while the liquids were still warm, using the small Bodum French Press outfitted with what is now a dual-filter---first the plunger forces the liquid through a wire mesh filter, then through the 5µ poly felt. It worked beautifully. One pass. Easy-peasy-Japanesey. Took about two minutes to filter each maceration. The great bulk of the 90 minutes I spent going from macerations ready to filter to finished extracts in labeled bottles was in preparation, filling the bottles, and clean-up after each filtering. Yield was from 60ml to 100ml of final extract for each tobacco blend.
I won't know for quite awhile the actual effects of this one-step filtering method on flavor and performance (coil/wick gunking), which is why this is just an interim report. Each extract needs to steep for a week or so, and then I'll want to log considerable time with the DIY NET juices made from the extracts to judge the flavor/performance factors.
For now, though, using the 5µ poly felt filter with the Bodum French Press for easy, single-pass filtering of natural tobacco extracts appears to be a big success.