We just changed our flooring from carpet to bamboo & the metal floor vent does not fit as well now, mostly because it goes further into the floor than before & the people that originally put in that ductwork did not cut the hole correctly. Anyway I am looking at the possibility of making a cover out of wood. First thing is I am not sure it will be strong enough. I came up with this first test design & am 3d printing it at 1/4 scale to see how it looks. I may not cut it on the CNC, but just use a 1" forstner bit for the 133 holes. I have the holes spaced 1/2" apart. By my area calculations these holes allow 34% of airflow relative to current metal opening. The opening is 14x24 & overall dimensions of the grill are 16x26. For the wood, I was looking at maybe using the thicker stair treads & glue 2 of them to get the 16" width. I did that before on a table & it worked well. So, I really only have 2 concerns, is it strong enough to stand on & does it allow enough air flow? I could also use smaller holes and more of them & that might get me more air flow, but of course is more to drill. I attached an image and STL file of my 1st version & it is nothing special.
HallWayReturnGrill_Rev6.zip (89.3 KB)