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I'm using a Dremel to smooth out the surface where the charcoal element is molded into the intake air housing. Even after you cut/sand the plastic surfaces so they're smooth, you can still see particles charcoal in the plastic (this must be an insert molding process where they mold the plastic around the charcoal filter element). So, wanting to get 100% of the charcoal removed, I keep Dremeling the surface farther down. You really have to get deep before "all" the charcoal is gone - just need to be very careful not to cut into the regular air filter's seal surface. Based on previous comments, I'm guessing that many don't dremel/sand the surface down to the point where 100% of the charcoal is removed - which seems a bit risky...
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