Back during COVID and the wildfires out west, I read about a bargain HEPA air filtration hack that could remove viruses and even smoke from the air. I started testing it out in my basement shop, and these many years later, it remains a full-time staple in my shop. It is also good for allergies and home renovation projects. This summer we had some guys rip out a bathroom, including tile demo, and this filter kept the dust out of the house.
This filter has many times the flow rate of a typical portable home HEPA filter. If they will change the air in a large room in 15-20 minutes, this will change the air in 3-5 minutes; fast enough to take particles away from where you are working.
Note. In general, you should NOT use a filter rated higher than MERV 9 in a standard home furnace. The airflow restriction is too great. Higher MERV filters can be used, but this requires a modified filter housing that can hold filters with much greater surface area. Don't just stick a MERV 13 or MERV 15 filter in your home furnace.
The Corsi-Rosenthal Box. A doctor and an HVAC engineer went together and designed the simplest possible filter, with the intent of reducing COVID viruses in public spaces. It consists of a cheap ($25) 20-inch box fan and 4-5 20x20x1-inch MERV 13 (good) or MERV 15 (better) filters (Box of 6, about $25 on Amazon). The filters are taped to the fan to make a 20-inch cube that can change the air in a typical room every 4-5 minutes (200-500 CFM, depending on the box fan, filters, state of fouling, and the box design details). Much cheaper than a HEPA filter, many times more capacity, and much cheaper to replace the filters.
Wikipedia. Corsi-Rosenthal Box.org/wiki/Corsi%E2%80%93Rosenthal_Box
MERV Filters. Air filters are rated for particle removal efficiency according to the above table. MERV 13 and MERV 15 filter are pretty effective below 1 micron. Additionally, the room air is being recirculated, so the multi-pass efficiency will be much better than the above single-pass ratings. Over 20 minutes the air may go through the filter 3-5 times, approximately doubling the removal efficiency.
According to the table, the filters can remove most smoke and agglomerated viruses after a few passes. My experience is that MERV 13 filters can remove welding fume and paper smoke after about 2-4 passes. Solvents and volatilized organics (part of the paint and burnt plastic smoke) are not removed.
Keep in mind that virus particles, as well as many other particles, often exist as agglomerations. They clump together, and in the case of exhaled particles, are in water mist. They will dry in the air, but still, they are typically much larger than the minimum size.
- In my home shop, the box uses 5 filters instead of 4, resting on furring strip spacers that keep it off the floor. This increases the flow rate. The bottom filter gets just as dirty as the others, proving that airflow remains balanced. The flow rate through each filter is quite low.
- Position the filter so that the air flows through the room in a pattern (plug flow). In my case, it is located under a shelving unit, near the table saw/sand/drill press area. The exhaust blows through under the stairs, and into an adjacent storage hallway. It then flows back to the work/fan area in a plug-flow pattern. The storage hallway never gets dust in it (clean air), there is no disruptive draft in the work area, and the dust is pulled steadily down and away from the work zone.
- Fan shroud. Cut a piece of cardboard or thin plywood to match the fan blade diameter, and secure it to the discharge side of the fan. This reduces re-circulation and increases flow about 10-15%. I made mine from 1/4-inch plywood and screwed it to the box fan.
- You can add a lightweight wooden internal frame (furring strips--not visible) to make filter replacement easier and to make it more robust against shop knocks. The filters are still taped in place, making them airtight (to each other, but not to the frame except where they seal to the fan).
- Remove the intake-side grill from the box fan; it is not needed, since the filters guard the blades. This reduces turbulence in front of the blades, slightly increasing capacity. In my horizontal installation, I lay the grill on the top so that tools can rest there, and to resist impacts.
Measured capacity is about 250 CFM with clean filters. It's pretty clean at this point, having been cleaned after the last significant project.
Because the fan switch is on the back side, it is powered by a switched outlet, so I can flip it on with a convenient wall light switch. It runs anytime I am using power tools, even occasionally. Also when sweeping-up.

My shop gets a lot of use and can generate a lot of dust. This is only about half of it. Crowded, but everything in its place.























