How To: Build Custom Sheetmetal Ductwork Transition | Step by Step Guide

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#ductwork #hvac #howto

Today I'm going to show you how to make A sheet metal transition on the field Let's do some work This video is sponsored by Blue on Upgrading the HVAC industry and by RLS RLS press fittings let you make a Permanent and reliable mechanical Connection in just 10 seconds without The need for brazing the RLS press Fittings were specifically designed and Engineered for use in high pressure HVAC And refrigeration systems they are fully Registered and listed to UL 207 for Pressures up to 700 PSI for more Information go to All right so we basically removed one That looked just like this And this is what it looked like so we've Got the new unit in place well somewhat In place And here are duct connections that we're Going to have to connect to And this is what we are Connected to on the unit itself so as You can see they are farther apart than The existing ducts so what I think I'm Going to do is actually split the Difference so center line to the unit Center Line of the dock so that way both Will transition out In a very uniform way I think that's Going to look the best So anyway this is what we're working With I'm going to show you step by step

On how we make a transition from a Dissimilar size and when it has an Offset First thing you want to do is when You're dealing with existing duct if you Have a drive on one side like this you Want to go ahead and get that prepped And bend that back out because you're Going to want to put s-lock on all four Sides so you want to go ahead and get All that prepped before you do anything Else Okay so the next step is going to be Getting the unit nice and square And putting it exactly where you want it On your pad make sure it's Square to the Building to the duct work again I've got The unit centered up so that way it's a Nice even transition to both sides and Then one thing that I like to think About if you have the opportunity Depending on your application is Have it to where this is going to be Less than 24 inches From your longest point so basically From here to here I'm sorry from from here to here or from Here to here 24 inches because your Sheet metal is 48 inch width so if you Can think about how you're going to be Basically cutting up your pieces of Sheet metal you're not going to be Wasting a bunch of metal and so Basically the way I'm designing it I

Should be able to get one Two three four pieces out of one four by Four piece of sheet metal Theoretically so That's one one thing to think about if You have the room to move it around and To get it closer obviously I could come In even closer but I think it's just Going to be it looks nice the way I have It sitting on the pad right now and uh So anyway I think this is going to work Out nice All right so what I'm gonna do now is go Ahead and measure all of my open sides Here so I can get all my s-lock cut go Ahead install that and then we'll be Able to start measuring piece by piece Foreign So when you're installing the s-lock What I like to do Is install it to where the metal that We're going to be installing will go Into the lip that's on the outside of This lip because the way the s-lock is Designed like right now I have this top One to where where it's going to receive That metal is actually going to go below The lip of the duct so what I want to do Is flip it around To where now It's now on the top side of the lip of The duct That's going to help it from getting all Bound up whenever you're installing it's

Going to make your life a whole lot Easier Okay so now that I've got all of the S-lock completely installed on the Existing duct that's ready to go Now on the openings of the unit I'm not Going to put s-lock on here for one it Has these rounded Corners I mean I could Put small pieces there but I don't think It's necessary all you need to do is Whenever we run our metal over we'll Basically just put screws like that and That's going to secure to the unit Itself so we are now ready to go ahead And measure Our pieces and the way I like to do it Is one piece at a time so and what I Want to do Is start with the most difficult side to Get to you don't want to start with the Top and then do the side and then try to Do the bottom so for this situation I Think it would be best to do the bottom Piece first Do this side second This side third and then do the top last And then move on to the next one over There and do it the same way So what we're going to do Is go ahead and measure that looks like 20 and a half inches is going to be our Length so that's one dimension And then the second dimension we want to Go from the furthest point

To the furthest point So because this is This is nice and straight what I can do Is measure from that corner all the way To here now you don't have to be exactly Perfect you can actually go a little bit Wider to where you again you can cut it And cut the excess off afterwards the Only Dimension that needs to be perfect Is from the unit to the duct because you Will be putting it inside the s-lock so It can't be too far So again I'm going to probably go past maybe one Inch or so that direction And looks like 20 inches is going to be A good number this way So we have Let's just call it 20. 20 by 20. Um That should work out well All right so having a nice work surface Like this Makes your job a whole lot easier these Two DeWalt tables they're very portable They the legs just kind of fold into Themselves So they're very nice to bring on the job All right So we talked about 20 by 20. Is what we're going to be measuring out Foreign so you just want to grab your Piece and go ahead and put it in the

S-lock and slide it into place Okay you can have since we made it Longer than we need we can just push it To where it lines up With This corner here Take your marker And you want to mark That corner this one's already perfect So we won't touch that Go ahead and hold it up where it's going To be You mark that corner And you mark your other corner here [Music] So now we take it out [Music] We're going to go back and we're going To cut this off We're going to cut I'm sorry cut this Off And cut that off do our cross break and Then we can come back and actually Install it All right so now all we're going to do Is Connect the Dots here go across from Point to point Mark that And then this one here Almost straight Okay Now we go ahead and cut this off All right so that's what we're looking At there the next thing we want to do is

Grab I like to use the hill more it's It's a pocket Bender or pocket break I Think is what they call it but it's just Got two little wheels on it and you just Hold it and then you can Uh basically makes make a nice little Cross break into the metal without using A four foot break if you've got a four Foot brake you can use that too Obviously but this is pretty quick You just want to go from corner to Corner and you can just uh You kind of just eyeball it like that I Like to use two hands And do that right there It helps if you're on a softer surface Like cardboard or wood you don't have to Press as hard But Still works pretty good Something like that As you can see gave it a nice little Cross break Um If you want I've seen some guys on Instagram they'll do it this way then They'll flip it over And then they'll go over about maybe I Don't know a half of an inch And they'll do it again Like so And it kind of gives it A little bit of an extra Strength and it looks pretty cool too

It gives it kind of that little X pattern Looks pretty nice So now we can go ahead and take this Back in there And get it installed and measure for the Next piece All right so I've actually changed my Mind I'm going to go ahead and put just A small piece of s-lock on here I think It's going to help me just keep Everything nice And solid while I'm installing it So I'll go ahead Get the bottom And the top installed Very nice All right so we've got a nice piece of Metal here It's not the cleanest piece of metal but That's fine Got a nice good cross break into it and Should go Just like this Get started As long as you push it Square it should Go in just fine So that's our first piece Now the second piece I'm going to Measure up is going to be this side Piece here So Should be the same Dimension but I Always like to measure anyway

Looks like We're at 21 and a half to get to it So 22 and a half inches Long Because we got one inch going into the Actual s-lock so 22 and a half And then as far as tall Again you want to measure from the Lowest the farthest points basically so This is lower than this and this is Higher than this so we want to be able To measure about an inch to two inches Below this point and one to two inches Higher than this point So if we look at this that's four inches Off the ground so we'll just say uh two Inches past So two inches off the ground So it looks like 24 inches tall So 22 and a half by 24. All right so one thing I wanted to Mention it's going to be very helpful Because this is not a straight line it's Nice and offset what you want to do is Take your piece that you've already kind Of pre-cut and you want to bend the one Inch lip a little offset to be that way It lines up with that and then it lines Up with this bottom piece and then the Same thing here you basically want to Bend this little lip to where it fits in There right that way once you slide it In place You can mark your four corners and it's

Sitting in there nice and uh nice and Flush and square to all the material That you're working with All right so now that I've got This piece all the way seated where it Needs to be it's looking pretty good I can go ahead and On these I'll mark all the way across But Obviously you can see that this is not Perfectly flat once we put some s-lock There it'll keep that nice and straight But I still scribe it all the way across Just to give me a a good good Measurement and then obviously here We want to Mark that point And then Mark this point as well Now we just need to take it out and cut The excess off Go from there This is the bottom this is the top so Once we are meeting up with the other Pieces that we've already installed what We have to do is add one inch to this Side because we're going to have to bend That lip up and that's what goes into The s-lock that we're going to attach on The the bottom piece that's already Installed Foreign Looks pretty good All right so I've already got the s-lock Installed on the bottom piece and on the

Unit went ahead and removed this side Because if you try to have all three s Locks on on at the same time it's going To be impossible to get that on so go Ahead and remove that start with the Bottom lip and get that installed first And work your way in To the unit s lock like so And then work your bottom piece all the Way in Like that Now you can take this Lock that you removed And you can Push it down from the top side like so It might help if you Open up both sides Just to make it easier on yourself Like that Now I can go ahead and get this piece Measured and get it all cut up bent Installed and go from there 22 inches So we're looking for a a piece that is 20 by 22. All right Foreign Foreign Looks pretty good Now we want to make sure we Bend this in The right orientation towards the inside Like so There we go Foreign

So you may be asking why am I using a Hand brake and the pocket break as well When I have a four foot brake sitting Here now I brought that just in case I Wanted to use it But what I wanted to show you is that You don't need the big tools like that In order to make a transition like this Out in the field You can just get a two foot bending bar And then you can get that Hill more I Think it's called a pocket break I'll Leave a link down in the description for You that way you can check it out pick One up for yourself but super nice to Have having those small tools with you Where you can easily make a transition Like this and not have to carry around a Big four foot break it's just really Nice All right again start with the bottom Just the corner Slide it in Just like so Foreign All right so we got all three sides Now we just need to get the top Measured up and we'll be in good shape So as you can tell I've been building This and I have not put one single screw I haven't used any tape everything is Just being held together currently with S-lock so that tells you that you know Obviously when I get done I'm going to

Go around and put screws in that way It's nice and solid but this tells you Just during the assembly process how Well this works so anyway I'm going to Go ahead and get this measured up and Get this last piece installed Foreign So since this is the last piece we have A one inch lip on both sides because That's what's going to go down into the S-lock on the side pieces so you want to Make sure that you've got at least one Inch On on all sides So Probably need to bring it towards me Just a hair That looks pretty good The main thing I do is just mark it on That s-lock because that's where It's going to be going down anyway Foreign You could Turn it around and give it another Scribe here just try to get it a little Bit deeper Foreign The more you stay over the top of this Tool the more weight you can push on it The more Bend that you're actually going to get So It's helpful to stay On top of the tool as much as possible

Instead of reaching out I mean that That's a nice good cross break right There Foreign Back side is in this corner is in You just want to make sure that falls Into place There you go All right that looks really good I don't even have a single screw in that Just yet so Once I throw some screws if you notice I Didn't put an s-lock on here just Because Um this really I mean I guess I could Have slid this one in but there's really No sense in it I can put two screws Right there And it's going to be nice and solid As you can tell I mean there's a little bit of a gap Here A little bit of a gap there Not very much you can take your sheet Metal Hammer round off these little Corners a little bit But I mean other than that Nothing a little duck mud is not going To seal up just fine It's really solid And it looks great All right so there we go We have one

Transition completely finished Just got to get it screwed and sealed I'll probably put some screws in it but I'm going to wait to Throw some duck butter on it until I get That one built just because I will be Wearing that for the rest of the week if I do that So anyway I think this thing turned out Really nice And it's actually very simple To do All right so the process is going to be Identical for doing the supply side and I'm not going to bore you with doing Repetitive work like that so again it's The same process you just do one side at A time and as you're going around you Add that one inch lip to secure it with The s-lock and you're going to be good To go so for this particular job the Transition that we made obviously it's Not insulated but the other ductwork is It's lined on the inside so what I'm Going to do is I'm going to insulate on The outside and then I'm going to put Some metal over the top and sides seal That that way you know the ductwork is Insulated but it's also protected from The elements so anyway I really hope you Guys got something out of this video Give it a thumbs up if you did subscribe To the channel if you haven't already Until next time see you guys later

[Music] Foreign [Music]

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