Furnace Air

Why is my furnace air filter suddenly collapsing?

I have a Lennox down draft furnace. After adding a room and a couple ducts,my furnace filter collapses during use. It is not overly dirty. I am using a standard 1 inch filter. Not the mohair,but the reinforced paper. The filter has support on three sides. Is too much air now moving? There is also a small additional cold air duct installed directly above the filter. Would installing a 2 inch filter work better? Any help would be great. Thank you.

If you can fit a 2" filter in there, you absolutely should. You'll get better filtration, longer usage and it'll be less likely to collapse.
As far as why the existing filter is collapsing, the obvious answer is too much airflow through it, but on downflow furnaces, the filter mounted horizontally above the blower makes this more likely to happen anyway.
The additional return duct above the filter would certainly add airflow potential, and likely is the straw that broke the camels back.

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