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My cabin has a 16x25 filter in a spot that needs a 16x22 (doesn’t exist) filter. I fit a piece of wood to help wedge filter in tight and help minimize air sneaking in from the crawl space.

What would you do?

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If the filter is unavailable as you say then I would fab an oversized access cover to enclose the oversized filter and seal the unit.

14 gauge stainless steel because I deserve the best.
 

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You might find one of these return air filter grills that fits your air return duct and an available filter size. Then you can seal the old filter slot and change the filter from inside the house.
 
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If the filter is unavailable as you say then I would fab an oversized access cover to enclose the oversized filter and seal the unit.

14 gauge stainless steel because I deserve the best.
Dude, duct work is only made out of 20-24 gauge metal.
 

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Cut the filter then rig something to seal the end. My filter fits but I had to use a piece of channel and some duct tape to seal the end.
 

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My cabin has a 16x25 filter in a spot that needs a 16x22 (doesn’t exist) filter. I fit a piece of wood to help wedge filter in tight and help minimize air sneaking in from the crawl space.

What would you do?

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View attachment 856252
When I Google "16x22 furnace filter" they seem to be plentiful. Even home depot has 16" x 22.25." Guess I'd buy one of those.

https://www.google.com/search?sourc...hUKEwjS28-a6tLsAhVECM0KHZIIAAAQ4dUDCAk&uact=5
 

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Dude, duct work is only made out of 20-24 gauge metal.
Dude, we don’t do duct work in the shop but I can grab some 12 or 14g stainless and make anything I want.

OP asked what I would do.

And that’s what I would do.
 
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