HVAC Air Return Box Restoration with recycled wood and cull fiber glass 4’ x 8’ panel

We recently had a new heating and cooling system in stalled. I looked at the beat up air return box in the garage and decided it needed a face lift.

The photo above is what the box looked like before the restoration. The side and top corners were covered with drywall corner beads which were sharp and would cut your legs if you ventured to close to them.

I milled the wood from the pallet the condenser came on, stained it and finished it with spar varnish and used it for the baseboard.  

The the sides and top molding were made from wood from a bunk bed my neighbor threw out. 

The Side panels were made from a damaged 1/8” x 4’ x 8” fiberglass and resin panel that I found in the cull lumber cart at HD. That’s the damaged lumber and other stuff they put on a cart and sell at a  70 percent discount, and saved me a lot. 

They spray the cull lumber with purple, orange, pink or what ever  spray can colors that are available. The paint is easily removed with acid-tone which cleans and scores the surface and allows the Lock Tite to adhere to the fiber glass and wood better. 


I also used paintable caulking to seal all the cracks in the box to make it more air tight. 

Black indoor outdoor carpet was used for the top. I used 3/8” stainless steel staples to hold it down. 

The baseboards, sides and top molding is attached with Lock Tite Power Grip and an 18 gauge air nailer with 2” nails. 

This fiberglass resin panel is very tough and should take a beating in this high traffic area.

After milling the pine, gluing and air nailing them together, I routed the pieces with a 3/8” router round over bit. Then I stained and finished them. These pieces are the corners and top of the box. 

Thanks for visiting.