A better more efficient and odor eliminating homemade air purifier than just taping a 20x20x1 filter to a box fan. Sometimes you need to help clear the air in a dirty environment but dont want to use an expensive air purifier such as in a room after renovating and painting. Heres a cheap and easy way to build one.Air purifiers can be expensive and youve probably seen articles recommending to just put a 20" x 20" x 1" furnace filter on a cheap 20" box fan and POOF! instant cleaner air for not a lot of money. It really does clean the air pretty cheap.
Theres a problem with this though. These fans werent designed to be run with a filter. The filter will restrict air flow which will put a higher strain on the motor causing it to use more electricity and in worse cases could be a fire hazard. The higher the MERV rating (cleaning efficiency) of the filter the more stress it will put on the fan.
Dont worry! You can still have your cheap air purifier as long as the filter area is increased to decrease the effect of air resistance. Instead of using one 20x20x1 filter well use two 20x25x1 filters which increases the filter surface area over 250%. Its a little more expensive because youre using two filters instead of one but the increased filter surface area also helps the filter last longer before it gets clogged up and were saving on energy use compared to a single filter.
I cant take credit for the design, I found it via Marshall Hansen Design but Im using different filters.
I recently remodeled my basement and theres a lot of dust (including drywall dust and sawdust) and fumes from paint, cleaners and other building materials. Its an underground basement and mold has to always be a conern too. Because part of the space will be my home theater in the future I plan to get a more expensive air purifier thats smaller and quieter such as this Fellowes Quiet Air Purifier AP-300PH with True HEPA Filter
Filtrete Odor Reducing Air Filters 
The box is sealed very well. Not only is it taped but the seams are also glued together. To get the filters out of the box I cut the top where its perforated with a utility knife as shown.
Be careful not to cut too deep and damage the filters. Keep the box someplace safe to the side while we continue.
Theres a problem with this though. These fans werent designed to be run with a filter. The filter will restrict air flow which will put a higher strain on the motor causing it to use more electricity and in worse cases could be a fire hazard. The higher the MERV rating (cleaning efficiency) of the filter the more stress it will put on the fan.
Dont worry! You can still have your cheap air purifier as long as the filter area is increased to decrease the effect of air resistance. Instead of using one 20x20x1 filter well use two 20x25x1 filters which increases the filter surface area over 250%. Its a little more expensive because youre using two filters instead of one but the increased filter surface area also helps the filter last longer before it gets clogged up and were saving on energy use compared to a single filter.
I cant take credit for the design, I found it via Marshall Hansen Design but Im using different filters.
I recently remodeled my basement and theres a lot of dust (including drywall dust and sawdust) and fumes from paint, cleaners and other building materials. Its an underground basement and mold has to always be a conern too. Because part of the space will be my home theater in the future I plan to get a more expensive air purifier thats smaller and quieter such as this Fellowes Quiet Air Purifier AP-300PH with True HEPA Filter
The box is sealed very well. Not only is it taped but the seams are also glued together. To get the filters out of the box I cut the top where its perforated with a utility knife as shown.Be careful not to cut too deep and damage the filters. Keep the box someplace safe to the side while we continue. Step 2: Hinge Filters
Start by taking 2 of the filters out of their plastic wrappers and lay them one on top of the other with the air flow arrows pointing towards each other. With the Odor Reducing Fitlers this means the black, carbon sides will be facing each other.
With the filters lined up, tape one of the short (20") edges of the filters to create a hinge between the two filters as shown.
I decided to go with white duck tape so it looks a little nicer but it makes it hard to see in the photos against the white cardboard filter frame.
With the filters lined up, tape one of the short (20") edges of the filters to create a hinge between the two filters as shown.I decided to go with white duck tape so it looks a little nicer but it makes it hard to see in the photos against the white cardboard filter frame.Step 3: Tape Filters To Fan
Lay the box fan face down on a flat surface to mount the filters to the back making sure the bottom of the filters are about flush with the bottom of the fan and do not extend past the bottom.
Use a strip of duck tape to secure each side to the side of the fan.
Use a strip of duck tape to secure each side to the side of the fan.Step 4: Cut and Attatch the Cardboard
Cut out one of the large sides of from the cardboard shipping box, place it over the top of the of the filters and secure it with a strip of tape to the top of the fan. Position it so that its pretty even over both filters but it doesnt have to be perfect.
Using a pencil, trace around the filters (while pressing down the cardboard so nothing moves) to mark where the cardboard needs to be cut.
Lift the cardboard up (the front piece of tape acts like a hinge) and cut along the lines to trim the sides. By the way, I really like these Fiskars Cuts+More 5-in-1 Multi-Purpose Scissors
Repeat the process for the bottom cardboard. The other large piece from the box is seamed but its taped and glued and very stiff so it shouldnt be an issue but you can run a strip of duck tape over the seem if it makes you feel better.
Also keep in mind that the bottom of the fan has feet. I positioned the cardboard underneath the feet and then pulled the feet out to tape.
After taping up the sides of the bottom cover to the filters, I added an extra strip of duck tape all the way around where the filters/cardboard meets the fan for added support. The rounded corners of the fan means there might still be an air gap there so check them and add extra duck tape if necessary. On the bottom there are also some holes, duck tape over those as well. Finally, replace the feet.
Using a pencil, trace around the filters (while pressing down the cardboard so nothing moves) to mark where the cardboard needs to be cut.Lift the cardboard up (the front piece of tape acts like a hinge) and cut along the lines to trim the sides. By the way, I really like these Fiskars Cuts+More 5-in-1 Multi-Purpose Scissors
Repeat the process for the bottom cardboard. The other large piece from the box is seamed but its taped and glued and very stiff so it shouldnt be an issue but you can run a strip of duck tape over the seem if it makes you feel better.Also keep in mind that the bottom of the fan has feet. I positioned the cardboard underneath the feet and then pulled the feet out to tape.
After taping up the sides of the bottom cover to the filters, I added an extra strip of duck tape all the way around where the filters/cardboard meets the fan for added support. The rounded corners of the fan means there might still be an air gap there so check them and add extra duck tape if necessary. On the bottom there are also some holes, duck tape over those as well. Finally, replace the feet.Step 5: Seal The Back
Where the hinged filters meet the cardboard in the back, add another strip of duck tape for support and to seal any gaps.
Give another look around the seams to make sure there arent any gaps. If you find any, tape them up.
When using the fan, I always make sure that the cord isnt underneath the cardboard and instead is under the metal fan chassis, just incase something goes wrong and the cord overheats. Can never be too safe.
Replacing Filters
When its time to replace filters, use a utility knife to cut the filters free but leave the cardboard in place. Then just hinge and attach the new filters.
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