Magnetic Air Return Cover
Hide your ugly air return with a 1x4, some magnets, and a sheet of metal
Tools
- Miter saw
- Scissors
- Nail gun
- Pin Nails
- Wood Glue
- E6000
- Drill press/ drill
- 1” Drill bit
- Drill, Flat edge/square, level, measuring tape, Sander, pencil, painters tape
Materials
- 1x4x8
- Decorative sheet metal
- Round 1” magnets
- White duct tape
- Paint
- Filler
Cut list
- Cut down 1×4 into 1x2s and 1x1s
- 2- 1x2x27.75 from l-l
- 2- 1x2x22.75 from l-l
- 2- 1x1x22.75 from s-s
- 2- 1x1x27.75 from s-s
- Metal- 25.75 x 20.75
*all angles are 45°
Step 1
Clean the air intake the best you can with soap, water, and vinegar. Next I painted the surrounding wall of the air intake. Finally I paint the air intake with a roller and black paint from Ace Hardware. I do not recommend this stuff! It took each coat 4 days to dry! The paint did not go on smoothly and it is soo glossy it looks wet! I also had to put 4 coats! If you can, take it off the hinges or pull the whole thing out and spray paint it! I did not have that luxury.
Step 2
Cut the 1×2 pieces to cover the intake. Next drill holes in them for the magnets, I did 3 holes on the small pieces and 4 on the longer pieces. Glue the magnets in the holes with E600.
Step 3
Cut the 1×1 outside pieces. fit the 1x1s vertically to the outside of the 1x2s, which leaves 1/4 inch above the 1x2s, this covers the outside of the air intake. Next glue and pin nail the boards together. I let dry overnight. After it was dry I filled the cracks and corners with wood filler. Let it dry then sand and paint.
Step 4
Cut metal with scissors. Then glue the metal to the wood, over the magnets. I used duct tape to cover the sharp edges. Let it dry. Touch up any paint. Then fit/snap to air intake. Done!
Enjoyed the project?
Suggested materials:
- 1x4x10 (Lowes)
- Magnets (Lowes)
- Decorative metal sheet (Lowes)
Frequently asked questions
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