Never cared much for the way Keystone decided to install return air filters and grills in my 2014 Alpine.. it is a pain to remove 8 screws and try to find replacement cardboard backed filters.. plus they are rather pricey
After many years of excuses and such I finally came up with an improved version.. I replaced the OEM grills with same sized ones but of better quality and only 2 screw holes
Frame was fashioned out of inexpensive lattice wood and the edges mitered.. a T nut was used at each end sunk into the wood to provide a holding point at both ends of the new grills..
Brass thumb screws were used to dress up the appearance .. and it’s what Home Depot had in stock
Frame is mounted to the overhead ceiling material and dresses up the ragged OEM cutouts for the return ductwork as well as provides a smooth and finished appearance to the ceiling
Decided to use a 30x20x1 inch MERV 8 filter from Wally World as a starting point for filter material..
Some concern over how the filter material would be held in place and not sucked up into the return ducts .. the filter material was trimmed to fit the grill covers with a small cutout at the center end of each end of filter for thumb screw to screw into T nut anchored int9 the frame
I also added six small pieces of command strip material to aid in holding the filter in place against the grill but it really isn’t needed.
The grill frame pressed down all around the outer edge of the filter and holds it in
place..
I later found some bulk filter material that I may order and try but quite frankly the pleated filter with the plastic strips they use to hold the shape anchor the filter very snug..
Operational check of filter with AC fan on high shows zero evidence of filter trying to move from under the grill
One Wally World filter was enough material to make four filters for the new overhead return grill install.. Filter cost: $10
Some images of the existing OEM grill, the sloppy return ductwork cutouts and one side only 5 of the 8 screws actually were holding the filter grill in place
Two thumb screws is all that’s required to remove the filters now making the task much much easier.. cosmetically it .. IMO improves the overall looks of the ceiling
Link to my YouTube channel with a longer than anticipated video showing various stages of frame construction, filter material, and final product installed and checked for airflow and filter retention
https://youtu.be/fO5HllIYS8A