| once the expoy dried i went ahead and mixed up some more epxoy, this time i laid it in the same two spots as before, only this time it was ontop of the plexi, i filled in any gaps along these two edges and again waited for the epoxy to set in. once the expoy set in i started on creating an opening for the filter element to slide in and out of. using a dremel and a cutting wheel, i started on the underside (on the same side as the larger of the two vent doors) i cut through the black platic, JUST above the plexi glass we just added. this will be the top of the opening once all is said and done.
 http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2444.jpg ][/img] next we need to flip cover over and cut out the bottom half of slit. you want the lower slit to be as low as it can get without cuting into the circular part of the housing. so i just followed the flat, straight seem in the housing. (this cut will be made in a couple steps, due to shape of housing dremel cant cut across the entire width, at some points the dremel itself hits the housing before the blade can reach plastic to be cut out. so here are the positions dremel needs to be in to cut bottom slit. starting on the left, outside of housing, i used dremel to cut this one inch slit. then i had to reposition dremel from inside of housing.
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2447.jpg ][/img] to finish this lower slit i had to move dremel like this.
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2448.jpg?t=1338010134 ][/img] this is what it will look like once you are done with the cutting wheel and going onto the razor.
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2454.jpg ][/img] again, the dremel wont be ale to finish the entire cut, so go as far as the dremel will allow. this tiny section is all that is left but as you can see we cant reach it from the outside of housing, blade isnt large enough. so from here we will use our SHARP utility knife, and go SLOW, again as always. be patient. no need to cut ourselves or ruin the housing.
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2453.jpg ][/img] using slow and light pressure i cut from here:
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2462.jpg ][/img] to here:
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2463.jpg ][/img] then once i made 10-15 passes the plastic was cut through enough that it could just pop off, but before you try ripping it off we need to make the final cut along the bottom edge.
again, patience! nice steady pressure, nice and slow. from here:
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2465.jpg ][/img]
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2468.jpg ][/img]
to here:
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2466.jpg ][/img]
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2467.jpg ][/img]
once you make thoughs 15-20 passes with the razor the plastic will just pop out on its own
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2469.jpg?t=1338010738 ][/img] next go to the opposite end and use your razor to free that end the same way. nice and easy!!
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2459.jpg?t=1338010791 ][/img]
ok now that we have finished cutting out the slit for the filter, i took the dremel with the grinding wheel and just softened up all the edges so that there was nothing for our fabric filters to get snagged on. here is our newley formed slot and under it is the piece of plastic we removed:
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2470.jpg ][/img]
[img][ http://i202.photobucket.com/albums/aa24/preprodigy/IMG_2471.jpg ]"> from here you want to take both vent doors, remove old foam from all sides, de rust everything, and paint if you choose. then we will re foam everything, along with making our filters.
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