[PAINTLOVER]

Hi,

I am trying to self install an air filter return grill to make it easier to change my AC filter. Currently I have a 4 screw grill. my new return grill cover opens for easy filter access with unscrewing it from wall.

My current AC filter is 24W x 14H X1 and it fits in the return base perfectly.

I bought a Truaire 25W x 14H return grill from Home Depot #202529071

Questions, See attached pictures for detail:

1. The grill base I bought does not fit in the left side of my filter duct opening as I would have to trim the metal duct back and the wood 2x4 on the left side (See Picture) about 1 1/2 inches to fit my grill. Would this harm my AC system if I widened the left side of my duct opening to fit my air return grill.

My metal duct opening is approxiamately 24W x 14H

Trying to DIY to save the arm and a leg an AC company would charge to install it. Thank You for your advice.

 

[surferdude2]

If you can't get a proper size grill that fits and must use that one, consider cutting a 1" (or whatever is needed) section out of the middle of the frame and joining it back with a plate on the under side (pop rivet it maybe). Then cut the end flange away to the depth that would allow the grill to fit properly. Then remove the drywall back as needed to clear the grill as it extended into it. Might work... maybe apply some caulking where it looked necessary.

 

[PAINTLOVER]

If you can't get a proper size grill that fits and must use that one, consider cutting a 1" (or whatever is needed) section out of the middle of the frame and joining it back with a plate on the under side (pop rivet it maybe). Then cut the end flange away to the depth that would allow the grill to fit properly. Then remove the drywall back as needed to clear the grill as it extended into it. Might work... maybe apply some caulking where it looked necessary.

Thanks for your response! The next small return grill is 20 inch L x 14 inch wide and my filter wouldn't fit into it so I believe it would be too small for my situation.

Instead of cutting out a 1" inch section from the middle of the return grill I purchased, would it be ok to trim my metal duct opening on the left side about 1 1/2 inch and the wood 2x4 on the left side of my opening??

That would be easier for me to do, I just want to ensure I am not hurting my AC system by trimming the left side of my opening.

Any more responses and advice would be greatly appreciated.:smile:

 

[surferdude2]

If that's not a load bearing wall, then cut away as needed... may take half of the stud, no problem. You can modify the ducting and patch it as necessary at the corners with flashing/trim metal. That transition is easily removable if you need better access to rework things.

 

[PAINTLOVER]

If that's not a load bearing wall, then cut away as needed... may take half of the stud, no problem. You can modify the ducting and patch it as necessary at the corners with flashing/trim metal. That transition is easily removable if you need better access to rework things.

Thanks Surfer Dude,

How do I tell if it is a load bearing wall or not? To the immediate left of the return grill is a sliding glass door or do I need to send another picture so you can see to make sure?

 

[surferdude2]

If you have a single story house and it's an interior wall, chances are it's not load bearing.

 

[JBoot]

This one might fit: (take the one you bought back and exchange it/reorder)
https://www.homedepot.com/p/Venti-A...-Filter-Grille-White-Grille-HFG2414/304951721

 

[PAINTLOVER]

If you have a single story house and it's an interior wall, chances are it's not load bearing.

I live on the first floor of a 2 story Condo. It is an interior wall and I will use a reciprocating saw to carefully trim the 2x4 and a tin snipes to trim the metal duct to fit the new air filter grill in. Thank You for your advice.:smile:

 

[PAINTLOVER]

This one might fit: (take the one you bought back and exchange it/reorder)
https://www.homedepot.com/p/Venti-A...-Filter-Grille-White-Grille-HFG2414/304951721

Thank You for the information.

 

[surferdude2]

I live on the first floor of a 2 story Condo. It is an interior wall and I will use a reciprocating saw to carefully trim the 2x4 and a tin snipes to trim the metal duct to fit the new air filter grill in. Thank You for your advice.:smile:

That may be a load bearing wall, especially if it's near the center of your condo. and running parallel to the center line. It not a good idea to weaken it.

 

[sktn77a]

Why don't you just return the grill you bought and get a smaller one??? You can get 24x14 grills, which would reduce the amount of cutting significantly; or you could get a 22x14 grill and maybe use a 1x2 filler and a little drywall patch next to the wall. Filters come in both of these sizes.

I wouldn't go cutting anything when the right size grill is available.

 

[PAINTLOVER]

That may be a load bearing wall, especially if it's near the center of your condo. and running parallel to the center line. It not a good idea to weaken it.

Good idea, no need to take any risks when another smaller air filter grill is available. Thank You for alerting me to the load bearing wall.

 

[PAINTLOVER]

Why don't you just return the grill you bought and get a smaller one??? You can get 24x14 grills, which would reduce the amount of cutting significantly; or you could get a 22x14 grill and maybe use a 1x2 filler and a little drywall patch next to the wall. Filters come in both of these sizes.

I wouldn't go cutting anything when the right size grill is available.

Agreed, I will check into getting a smaller width grill ether 24 or 22 inches wide.
I haven't seen any 22x14 air filter grills but will keep looking.
Thank You for your suggestion:smile:

 

[sktn77a]

Here you go:

https://www.amazon.com/Steel-Return-Air-Filter-Grill/dp/B07583CQC3