How to repair a return air grill in the hallway?

QUESTION:

Recently I purchased a home that the only way to change the furnace filters was to change them directly from the furnace. However, there is a return air grill in the hallway but there is no place to put the filter. I thought it would take a 20x20x1 grill so I started cutting some of the sheet rock in order to replace the grill with one that I could actually place a filter in. Well to my surprise after cutting away some of the sheetrock the area should only be for for a 20x16 filter but now the the return air grill will not cover the area that I cut. How can I repair that to get it to work? Do I need to purchase a piece of sheet rock and cut out an area to cover the hole and then recut to fit the grill?

ANSWER:

The cheapest thing to do is get a grill that will fit your new hole. They're less than 10 bucks wholesale. Maybe that retail


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