When you give an engineer a cookie

When your house has non-standard floor registers, you manufacture your own covers.

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Just a note on this process, I needed to make thru-cuts, so I placed the stock on MDF slats so that it can plunge all the way through without using a waste board (that currently doesn’t exist). MDF is super flat and supports the work from below when it cuts the final contour. My table surface is a laminated top, so as needed I can raise it up just enough when needed.

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John just went through this process myself.

2 suggestions.

Be careful that you have the same or more airflow as the vent you are replacing. Your opening sizes look right but your gaps between are kind of large which means you are probably reducing CFM. Secondly be careful with using MDF where there may be moist airflow. Most AC leaves condensate when the cold air hits the moist air of the house. The vents take a lot of abuse and at some point your finish is going to get worn through. I coated mine with a layer of epoxy to keep the MDF sealed. Time will tell if this was a good idea.

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