Magnetic Air Return Cover

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!