Before - old loose filter

Before - old loose filter

In 2003, new furnace & A/C was installed. They didn't change the intake box nor filter slot so the...

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Uploaded on Feb 20, 2012

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Before - inside top

Before - inside top

This is how much filter area is wasted due to the size mismatch between the old intake box and the new...

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Uploaded on Feb 20, 2012

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Before - inside middle & bottom

Before - inside middle & bottom

There's no support rail nor guide at the bottom of the filter slot, only a narrow ledge to sit against at...

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Uploaded on Feb 20, 2012

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Raw Materials

Raw Materials

I went to the local home supply store to see if there's a pre-made assembly for this purpose...and of course...

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Uploaded on Feb 20, 2012

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Pieces cut for channel

Pieces cut for channel

Cut off the pre-formed edge of the sheet, then measured & cut two strips 25"x1-3/4".

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Uploaded on Feb 20, 2012

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Channels

Channels

Bending tool works well, and with the shallower slot makes the 3/8" lip I want on either side of the 1" center.

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Uploaded on Feb 20, 2012

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Channels & clips

Channels & clips

I cut off the "remainder" part of the sheet, then pieced it out to make clips to retain...

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Uploaded on Feb 20, 2012

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Clips

Clips

Of the four clips I made, I didn't use the one at lower right - I decided it would give a neater result to...

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Uploaded on Feb 20, 2012

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Outside - bottom channel in place

Outside - bottom channel in place

Bottom channel's in place, retained by the clip joining the intake box skin to the channel.

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Uploaded on Feb 20, 2012

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Inside - bottom channel in place

Inside - bottom channel in place

Sheetmetal screw through clip and intake box skin at rear, channel slid under clip.

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Uploaded on Feb 20, 2012

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Block-off plate with integral clip

Block-off plate with integral clip

As mentioned before I decided to integrate the upper front clip with the block-off plate.

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Uploaded on Feb 20, 2012

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Block-off plate installed

Block-off plate installed

Upper channel inserted exactly as planned.

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Uploaded on Feb 20, 2012

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Block-off plate and upper channel

Block-off plate and upper channel

Upper rear clip has one screw above and one below, with a double-fold to locate the channel between.

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Uploaded on Feb 20, 2012

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Block-off plate and bottom channel

Block-off plate and bottom channel

Block-off plate end folds under the intake box, contacts the channels at top & bottom.

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Uploaded on Feb 20, 2012

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Inside - new filter installed

Inside - new filter installed

Test fit of new 16x25x1 filter in channels, right on the first try.

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Uploaded on Feb 20, 2012

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Finished product

Finished product

All buttoned-up and ready to run. Much better filter fit now!

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Uploaded on Feb 20, 2012

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Today's recolor

Today's recolor

Been about a month, so it was time to redo the color.

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Uploaded on Feb 12, 2012

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Available for sale...

Available for sale...

Saw these in the store...for 69 cents. Coincidence?

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Uploaded on Feb 4, 2012

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