Grue's photostream  

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

All rights reserved

Uploaded on Feb 20, 2012

0 comments

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

All rights reserved

Uploaded on Feb 20, 2012

0 comments

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

All rights reserved

Uploaded on Feb 20, 2012

0 comments

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

All rights reserved

Uploaded on Feb 20, 2012

0 comments

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

All rights reserved

Uploaded on Feb 20, 2012

0 comments

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

All rights reserved

Uploaded on Feb 20, 2012

0 comments

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

All rights reserved

Uploaded on Feb 20, 2012

0 comments

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

All rights reserved

Uploaded on Feb 20, 2012

0 comments

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

All rights reserved

Uploaded on Feb 20, 2012

0 comments

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

All rights reserved

Uploaded on Feb 20, 2012

0 comments

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

All rights reserved

Uploaded on Feb 20, 2012

0 comments

Upper channel inserted exactly as planned.

All rights reserved

Uploaded on Feb 20, 2012

0 comments

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

All rights reserved

Uploaded on Feb 20, 2012

0 comments

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

All rights reserved

Uploaded on Feb 20, 2012

0 comments

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

All rights reserved

Uploaded on Feb 20, 2012

0 comments

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

All rights reserved

Uploaded on Feb 20, 2012

0 comments

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

All rights reserved

Uploaded on Feb 12, 2012

0 comments

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

All rights reserved

Uploaded on Feb 4, 2012

0 comments