thzinc

Workshop air filter

Ongoing project to keep my garage workshop air reasonably clean and easy to breathe.

Workshop air filter  🗒️

Designing a Corsi-Rosenthal air filter box for my garage workshop

It’s been over a year since I last wrote about building an air filter for my garage workshop, but I’m finally making progress toward designing and building my own Corsi–Rosenthal Box. I recently received a nice miter saw and decided to try my hand design and building with US dimensional…
Rendering of workshop air filter showing just the nearly-cubic wooden frameTechnical drawing of top plate with a 16-inch hole for the fan and markings for screw placementTechnical drawing of the sides showing the arrangement of the 2x4 blocks and markings for screw placementTechnical drawing of multiple views of the assembly with indications of the four unique lengths of 2x4 blocks needed
Workshop air filter  🗒️

This is one overbuilt Corsi-Rosenthal air filter box

After a bunch of design and planning out the cuts, I had most of a Sunday to work on cutting lumber and assembling my Corsi-Rosenthal box. I started with the miter saw and the 2x4s since that was the least-familiar material to me. I did a little bit of planning…
Photo of workbench centered on miter saw with 2x4 prepared to be cut; some finished 2x4 cuts lie to the left of the sawPhoto of finished 2x4 cuts organized in groups of 4 lengths, each with 4 lengths for a total of 16 pieces; the lengths of each piece are lightly penciled on the edgesPhoto of particle board laying across two workbenches with a gap to allow the circular saw to cut the board; a metal rail is clamped to the board to guide the sawCloseup photo of 2x4 with pencil markings for each hole, with drill in frame
Workshop air filter  🗒️

Gaskets, casters, and filters

The box was so close to being done. Just needed something to keep the filters in place, but also allow them to be easily removed. I decided on using weatherproofing gasket with adhesive backing. Now the filters fit snugly, but are still easy to remove and replace.
Photo of rubber gasket stuck to the uprights in one side of the filter boxClose-up of ~1/4 inch rounded notch cut into radius of hole where fan pulls airPhoto of completed filter box on casters with filters installed and fan sitting on top