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Picture of Air Vent Cover with USPS Box
So, you just ordered 200 boxes from USPS because they were free and you've probably used close to none. Heres a neat project I made on how to utilize the smaller boxes. Don't have any boxes? Go to USPS.com and order some, they're free.
 
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Step 1: Get a Box, Razor, and Packing Tape

Picture of Get a Box, Razor, and Packing Tape
In this picture I have two boxes because I wasn't sure how much I needed, get two in case you need another. Then get a razor and/or scissors and packing tape from officemax, walgreens or where ever.

Step 2: Tape up the box

Picture of Tape up the box
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Next get the box so its fully folded up, as if you were about to ship something in it, but instead tape everything top and bottom and then the sides (See pictures for reference) This step makes it almost air-tight.

Step 3: Grab your vent

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Get your vent out of its hole and close it and put it on the top or bottom, doesn't matter, then outline the part where the air comes through. I would put it more to one side if the vents on a wall.

Next, cut the outline you just made with your razor and pop out the cardboard.
Keep the cardboard that you just cut out, you will need it later.

If you wish put the vent in the hole to test if it fits... Mine does, perfect fit =)

Step 4: Put it over your vent and cut a hole

Picture of Put it over your vent and cut a hole
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Simply put it over your vent and check if any air comes out the top or sides, it should a little at the bottom. Now mark with the razor or a pen which way you want the air to go in the vent, I want mine to come out the side pictured so I cut a little gash in the middle of it.

Next I got my razor and just cut a hole, didn't really madder on what size, but its pretty big on mine. Once again, keep this peice.
simharry7 years ago
isint this a bit of a fire hazard?
did u see the movie F 400 something degrees ???????????
rcfz (author) 9 years ago
Are they going to raid my house because I just made a vent cover for my self?
georion rcfz5 years ago
Possibly---if they do you'll have no one to blame,but yourself --for Advertising!!!!!
Tchnclfl6 years ago
This would be interesting enough. Too bad what you just did is a federal crime :O. It's illegal to use the boxes for anything but shipping using the method the box states (Priority mail, International, etc.) It was well written though, and if you're not worried about the "fuzz" (you'll be fine) then it's a cool little project :P.
The US postal service don't ship to Canada do they ?
simharry7 years ago
still...... great instructable, i like the resourseful ness of using the free things around you, of course i think that is what instructables kind of is about. GREAT INSTRUCTABLE.
sixfootgeek8 years ago
They used to be great for UPS and FED-EX as well, just pull apart the glued edge and re glue inside out. The problem is now they stamp priority mail on the plain side as well. Still good for home use though!
karen6088 years ago
Well I use recycled boxes - I get mail all the time! and the person with 3000 boxes ought to mail out 3000 presents to all the people here at instructables.
bookman109 years ago
It is actually illegal to use these boxes for anything but mail. Read the fine print at USPS website.
Great instructable! I like it because it solves a common problem on the cheap using interesting materials. Looking for something to do with your boxes? How about http://www.fedexfurniture.com/ .
rcfz (author) 9 years ago
Haha I just ordered about 50 small and 25 long ones ;) Haven't used them at all expect for now, I used to long ones to guide the air upwards when its behind a bed. I'm still brainstorming for more ideas.
Bos.jon9 years ago
Wow I hate it when I mess up HTML like that.
Bos.jon9 years ago
Ahahaha
funny story.
I ordered 3,000 boxes from the USPS
<img src="http://img109.imageshack.us/img109/2893/photo0606050012cq.jpg"</img>

I got that on my doorstep for like 3 days in a row.
And they're all in my basement, but now I have something to with 1/300 of them.