Looks like I need to fab up a cover and seal it up
A flat piece of tin with two 90 degree bends is simple, but I believe the filter sticks out about 1/2"
I will figure something out this weekend
The townhouse my wife lived in when we met had an exposed filter like you have with no cover. Or at least that is what I found out. The previous owner used duct tape to cover the filter hole/slot up. When I first saw it I was like WTF is that. When I removed the tape, and pulled out the filter, it was so packed full of dirt you couldn't see any light thru it, not even a bright shop light I put on one side to shine light on it. That filter must have been there at least 10 years, and I could not figure out how any air got thru it at all.
I bought my wife a new reusable filter that you could take out and clean, and I made a simple bent sheet metal cover as you are describing. It had to also bend a bit around the filter as it stuck out like yours does. I went one step further and also bought a cheap long piano hinge to mount the cover to the furnace, along with a little magnet I put on the other side of the cover.
The hinge allowed the cover to open up more like little door, and also keep it attached to the furnace so my wife could not loose it. And the magnet helped keep it closed nice and tight without having to use any tools/hardware to open it or close it.
That setup was pretty cheap, and it made it easy to open up the filter cover to remove and clean the filter without the possibility of anyone loosing the cover, or in my wife's case, stepping on it and terminating it as she seems to do with just about anything that is on the floor.
Jim