How to Make a FILTER RACK in a Plenum or Duct so that the Filter Slides In Smoothly

How to Build a FILTER RACK in a Plenum or Duct so that the Filter Slides In Smoothly. This is how to Measure, Cut, Add the Slide/Slip/S-lock, Cut the U Channel, Snap Lock Punch the U Channel and Rivet it so that the Filter slides in and out easily along with how the Door Connects. Supervision is needed by a licensed HVACR Tech while performing tasks as Experience and Apprenticeship garners Wisdom and Safety.
Tools Used In The Video
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⚠️ Disclaimer:
Information in this video is intended for educational purposes only. Any work related to the topics in this video should be performed by licensed technicians or by apprentices under the supervision of licensed technicians. AC Service Tech LLC is not responsible for any possible damages or injuries caused by the use or misuse of any information provided.
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#hvacr #hvacr #hvactrainingvideos #hvactraining #hvactraining101 #acservice #acservicetech #sheetmetal #duct #ductwork #plenum #sheetmetalwork #sheetmetalbending #filterrack #plenum #ducting
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[@acservicetechchannel]

Our Inverter Mini Split Resources: Mini Split Book on Our Website- www.acservicetech.com/mini-split-book Mini Split Paperback on Amazon- amzn.to/3ytHJSs Mini Split Paperback on TruTech Tools- www.trutechtools.com/BooksGuides?aff=8 Mini Split E-Book on Google- play.google.com/store/books/details?id=HN-iEAAAQBAJ Mini Split E-Book on Apple- books.apple.com/us/book/id6445178399 Our Single Speed and Two Speed Air Conditioning Resources: My Paperback and E-Book: www.acservicetech.com/the-book My Paperback: www.amazon.com/shop/acservicetech Read the book reviews on Amazon! Check out our new Articles at www.acservicetech.com/articles Support the Channel by purchasing tools through Tru Tech Tools! Use this link www.trutechtools.com/?Aff=8 Save 8% at checkout using code "acservicetech" Tool List- www.amazon.com/shop/acservicetech Support- www.patreon.com/acservicetech For those that are looking for the tools used in the videos: (Linked Below) Here is the link for the Malco 3" Blade Combination Snips- amzn.to/2dz7Ejc Here is a link to the Wiss Right Tin Snips- amzn.to/2rGnBvX Here is a link to the Malco Sheet metal scribe- amzn.to/2qCwu9D Here is a link to the Wiss Bulldog snips- amzn.to/2rd1Dz5 Here is a link to the Malco 90 Degree Right Hand Vertical Snips- amzn.to/2qHHpu4 Here is a link to the Malco 90 Degree Left Hand Vertical Snips- amzn.to/2qHF564 Here is the link for the Hilmor 12" folding tool- amzn.to/2d9VTPR Other tool links can be found in the video description section. ACSERVICETECH is a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for sites to earn advertising fees by advertising and linking to Amazon.com.

[@kgl1056]

So you have the steps and how to take the measurements in the book?

[@brokensmile8487]

Where can I find that U channel?

[@edwardluth7740]

Can’t see inside and bottom area. No good.

[@richhayner1208]

I couldn't remember how I'd learned the corners on the drain pan so I watched your vid as a refresher, two minutes in and it came back quick. You did a great job on that one and it got me hooked so I checked this one out. Now, I think I'll be using this method for building them in, instead of the one I learned years ago. Thanks for a great video. Keep em coming

[@acservicetechchannel]

Thank you very much Rich!

[@nowayjose20]

Thanks for showing us this! This is a perfect solution to my existing 60 year old return ducts.

[@jamesward9169]

great video. Have never done any duct work before and was able to easily build my filter rack using this technique. Thanks!

[@acservicetechchannel]

Glad it helped!

[@battleofthewillwhatilikela4650]

Exactly the tutorial I needed to make things simple for myself. Thanks, Bud!

[@acservicetechchannel]

Great to hear!

[@axeloberg9596]

Great insights on left and right handed snips. I never knew! A++

[@paulhaynes4965]

Great step-by-step video. Save me $$$ calling the HVAC contractor.

[@sneakypoof]

Love it, straight to the point and simple

[@dandearman2871]

I've learned a lot from your channel. Thanks.

[@aircooledtx]

Nice channel rack, not to many techs can bend metal now . Good Job. Ole Timer, we built these in 70's.

[@acservicetechchannel]

Thanks Michael Lee!

[@superdutyscaler6823]

I'm 35 and have been making my own metal for jobs since I was 14. Guess it was a good thing my grandfather was a great teacher

[@gene-khvacr]

great Vid to the point WELL DONE SIR keep it coming friend

[@acservicetechchannel]

Thank you! I am glad you enjoyed the Video!

[@gilmarmencia8296]

THANKS VERY CREATIVE!!!! Nice job 👍

[@Zepsswansong]

Awesome work, thank you!

[@jimbola77]

very nice job!!!!

[@joemikhaiel3710]

I appreciate sharing the knowledge

[@acservicetechchannel]

So nice of you

[@NMranchhand]

Ha! After you showed me how to use the three-pack of snips on the gutter downspout, I came here to get more of your sheet metal experience, saw this, rushed downstairs in my new/old house and discovered that I didn't have a door! Now I'm making one. You're the best!

[@acservicetechchannel]

Ha that's great!

[@Nicoya]

Great video. I'd love to see a follow-up for filter rack options where space around the unit is more limited, like in a closet where a slide-out panel wouldn't be able to slide out to the side. I've got a downflow gas furnace in a closet in my home, and the flue comes up right in the middle of the plenum, so it's posing quite a challenge for me if I want to relocate the filter closer to the furnace.

[@bigjoshlevine]

I was wondering how to make it so the slot could be closed up behind the filter. Thanks!

[@PaulHVAC1]

Good video ACservicetech, I enjoyed it

[@acservicetechchannel]

Thank you very much for the Comment! They are always very much appreciated!

[@acservicetechchannel]

Thanks for your comments!

[@TropicalBoneFlorida]

Thanks for the helpful vid!

[@acservicetechchannel]

Glad to help!

[@wdckellogg]

Is there any way to remove one like this and then cut the slot wider for a thicker filter insert? Do they make a wider filter chanel for this type of plenum duct?

[@utubebp1]

Hi thank you for sharing this instructive video. I need to add a filter rack to the existing plenum box above the blower compartment of an old Rheem furnace. It is in tight space in the garage. Do I need to take down the plenum box to rivet u-channel to plenum box, or maybe access through the blower compartment ?

[@whitesheatingairappliancer7101]

Great video thank you.

[@acservicetechchannel]

Thanks Ron White!

[@rogermartin2176]

Question about your U bend, where did you get it from?

[@StuckInNE]

That about how i do filter racks. I put mine in the return air drop elbow tho. I make my access hole 3" wide (i use 2" filters), we've had problems with customers not being able to get the filter out if the access hole is too narrow. So i give them an extra 1/2" on each side of the filter so they can grab it. - Good video, btw.

[@acservicetechchannel]

Awesome, great customer practice, thanks StuckInNE!

[@josephgriffy5954]

Great vid! Can this same method be used so that the filter slides in long ways from the side? I don't see why not but thought I'd ask.

[@waltw8230]

Interesting, we don't have sheet metal duct here in south Florida but I learned a lot from this thanks

[@acservicetechchannel]

Thanks Walt, do you mainly have fiberboard?

[@waltw8230]

acservicetech yes

[@waltw8230]

99% of the time and i hate it esp the older the insulation gets everywhere

[@brandoncoldcall]

Hey I’m trying to make a filter rack thing to use as the exhaust filter housing in my diy collapsible paint booth. Do you just use any type of u channel? Also can i use some type of adhesive to get it to stay

[@felipeballi7679]

great job, nice video

[@acservicetechchannel]

Thanks Felipe!

[@joedoken7376]

Thank you 🙏🏼

[@acservicetechchannel]

You’re welcome 😊

[@Balticblue93]

I would like to know the best way to make a filter rack for 5" filters or where to buy a 5" filter box or rack to add to systems. Not the powered units but just a basic rack or box that accepts 20x25x5" filters. Any input or point me in the right direction?

[@MrWitty45]

Nice work, you can do this with 1 pair of snips Midwest with the off set. Blade keeps metal from curling.

[@acservicetechchannel]

Thanks!

[@jimgillett1184]

Ya lol you can tell he's a Service Tech and doesn't know what kind of snips you use. Offsets and throw them Straight Aviation snips in the dumpster. Sorry just saying. 31 years of installation here

[@RodrigoRamirez-fc5hv]

You are welcome.

[@anointedbro]

Good job

[@acservicetechchannel]

Thanks Donald!

[@smkaur]

I am ordering tools. Can you give guidance for a four inch filter doing the same thing? I’m ordering the tools now. Thank you for this great video.

[@brandoncurnutte8235]

Come out to WV and make one of these for me! I need some ductwork in a bad way!

[@acservicetechchannel]

Ha ha that would be a long trip! Thanks

[@smkaur]

Did you create the slide, slip, or s-lock pieces custom?

[@petesingh292]

Hi you should start a class on line the very basic sheet metal work

[@MitchellPetersonJr]

This is exactly what mine looks like for my furnace. Except the hack who did the work used sheetmetal screws instead of rivets. Changing my filter requires me to tear the cardboard from the top to get the slide to fit.

[@work4rsl46]

that is just what I was looking for, the new hvac system in my house when I bought it has no slot. I literally have to take the outer cover off then remove screws to expose the squirrel cage and slip it in there.

[@MRSEEK100]

The person that installed the vent for the filter at my parents house( a long time ago) didn’t put a rack like that, is there anyway to do it with out having to disconnect the vent from the furnace itself??

[@snowww816]

How would that attach to the top of a downflow (American Standard 80) 16x20 .

[@tommeyers974]

Nice video. Where can I get some "U Channel" ?? Thanks. Tom

[@smkaur]

Custom U channel?

[@cookytrix]

i want to know how to get those "break" lines in the metal at home. the X in the middle for noise control. i have some 8" oval forced air duct that pops

[@acservicetechchannel]

If it is existing and oval then you could try to screw a 10' section of s-lock cleat on top of it to stop it from popping. You can't crossbreak oval piping, thanks

[@rpsmith]

1 inch filters for new installs have outlived their usefulness but otherwise a good video!

[@Ratseeker]

Where would I buy the filter rack made for 5" filters?

[@shawnjackson1223]

I never done this before but want to try it cause my hvac system was installed with no place to put a air filter. No compartment or anything. Need help

[@Ericbakereb1]

If your return grille is on a wall, you can do a filter grille, which would be simpler than this. In your situation

[@pondboggen]

watching video. and recently having a nightmare of a installation of someone locally, of a new furnace, a/c setup. the air filter came as a package deal (cold drop return) with 1" air filter installed just after the 90. as it routes into the furnace. the sheet metal edges = sharp. you have your S cleats. that is fine. on one i have (manufactured) i cut my fingers on the sharp edges. nice job on the S cleats! the other issue was just bloody getting a hold of the furnace. there is no "finger groove" per say. to grab a hold of the "air filter" once it is slide in, and trying to pull the air filter back out. it is like you need to stab your finger into the air filter itself to even think about getting a hold of the air filter to pull it out. might suggest cutting a "notch" for lack of better word. on one of the 1" width sides. about 1/2" to 1" down the side. so when the lid slides off. it reveals a little notch you can place a finger and pick filter up and out. if anything perhaps make the entire 1" width 2 to 3 inches in width. and put the "rail" in the center with a wider lid, so someone can grab a hold of air filter with a thumb and pointer-finger. would be nice to see some sort of "foam" or "gasket" vs the S cleats. 1/8" thick i am guessing more than enough thickness. just something so lid creates an air tight seal on the duct work, but also has some spongy-ness in the center, so the foam itself presses down on the air filter. to keep air from blowing around the air filter.

[@pondboggen]

and yes loved the video. nice and easy!, awe so wish you were my installer!

[@acservicetechchannel]

Well actually you could have a sign guy cut you a 3"x21" or 3" X17" flat magnet like the kind that you would put on a car door for a business. You could measure the distance and put one side sticky foam down the center so it seals tight to the filter but does not push the magnet off. Many of us used to use magnets to cover the hole without the s cleats before all the duct pressure testing came into effect for testing duct leakage. They didn't fall off but I don't know how it will go with the foam pushing against the filter. Bend a u with the end of a coat hanger to snag the inside edge of the filter to pull it out and leave the hanger there by the return for future use. Thanks

[@giuseppe-fn5wp]

great video!!! any new ductwork videos in the future?

[@acservicetechchannel]

Not at this moment but certainly yes in the future, thanks!

[@WhiteWakedNProud]

how to cut out a rectangle in sheet metal, the long way. neat idea on the door though, i like it

[@RodrigoRamirez-fc5hv]

That is a nice Rack.

[@acservicetechchannel]

Thanks Rodrigo!

[@cagedruss]

Race car fabricator here. Red and Green shears can cut either direction. They are left and right because the waste material exits the left for red and to the right for yellow and green.

[@andriiflach7008]

Where do I get the 1” U Track?

[@johnmiller102]

Nice job. Wouldn't it be easier to just buy a ready made filter rack? I guess there are times when you'd have to make one yourself.

[@acservicetechchannel]

Yes, I usually use the 4" filter racks so the homeowner has the option of the 1" or 4" filters. Otherwise I just build them into the plenums especially in tight spaces. I do not use the filter racks that come in the air handlers as they are a non stock size and I do not use washable filters. Thanks

[@MusicLuv80]

Sir, I have a concern. I put the filter and the top part of the filter fits right on that back of the filter rack but the bottom doesn't fit by an inch but when I push the bottom part of the filter then the gap does close in more but still have good half inch gap between the filter and the filter rack. I have tried 6 filters just to make sure and the AC technician also agreed that filter rack wasn't built straight in the back. My first concern is we had turned on Fresh Air Ventilator for about three month and there were constructions in the near area as well. I did turn off the Fresh Air Ventilator last week. So my concern is would any bad air come into the house? And is this filter rack fixable as well? The AC technician who came out because we had warranty on it told us it is fine and doesn't need to be fixed and that even with the gap no debris would have come in and filter would have took care of everything. I asked him several times, I didn't feel comfortable since I have kids. But he said it is okay and won't fix it. Could you please give me a good helpful tip please.

[@acservicetechchannel]

Why cant an extra piece of galvanized tin, 1" higher be added on the side of the existing u channel or another uchannel mounted inside of the existing one that has higher sides to hold the filter. It would have to be riveted into place so as to not stop the filter from sliding freely. I would just have a tech do that thanks

[@MusicLuv80]

Thank you for your answer. I will speak to the tech once more. Hopefully it all works out. Thanks

[@BrodyProductions3]

everybody loves raymond

[@imstevemcqueen]

3 sided plenum with 2 individual panels incorporating the filter opening much better that s-lock that falls off the top...nice filter slide though

[@hangngoaigiare]

Hi sir i would like to have a hand on personal training how to install duct work. Do you do that? What the cost?

[@acservicetechchannel]

I presently don't at the moment, sorry!

[@coach7636]

I loved this until I went to remove the filter.... with the slot only being as wide as the filter I can’t get in and grab it. The next one I do I’ll make the opening big enough to grab the filter! Lol. What do you do to get it out?

[@aperlia6603]

Mine is tight like that. I use 2 butter knives lol.

[@MsckMatt]

What you could do is put some tape on it with a strip coming off it if that makes sense. Thats how i get mine in and out easier and can still keep a tight fit

[@JeremySharpSMSG]

Get some metal banding and bend a "U" with some tabs at the end, that can wrap around the edge of the filter

[@lilliput1orig]

I found that the filter in my AC return air plenum has bowed in on the filter sides thereby letting dusty air in. The sheet metal man only put the U tracks at the top and bottom of the plenum. The sided of the filter were not restrained/supported so the filter bowed. Note this could happen on your installation because the service side of the filter track does not have side support on the filter. There should be an angle attached to the downstream part of the service side so one leg of the angle would restrain the downstream side of the filter and the other leg of the angle secured to the sheet metal plenum.

[@lilliput1orig]

My solution was to tape 3/16" thick x 1"wide x 20" (filter height) long strip of wood at the downstream face of each of the filter side. The filter and wood strip would fit in the top and bottom U channel filter track. The ends of the wood strip would be secured by the filter track and they would act like beams supporting the sides of the filter preventing it from bowing in from the suction created by the fan. There also was a half inch gap between the top of the filter and the top of the top U channel filter track. I closed this gap by inserting a half inch diameter PVC tubing 24" (filter width) long.

[@feyrband]

Might want to use some 1/4 inch sheet metal screws from the outside to suck the wood against duct, as insurance in case the tape fails

[@rafaelabreo9988]

where can i buy something like that for my unit

[@acservicetechchannel]

Are you talking about the actual filter rack or the magnet from the previous comment? The filter rack is actually made out of u channel, s-lock, and a small 3" piece of metal. The magnet could be purchased from a professional sign and sticker maker, maybe a craft store, or possibly online but I usually buy mine precut from the local sign maker.

[@MusicLuv80]

Is it okay to have 6 holes in the filter rack? I heard air in the attic isn't good also having fiber glass in the attic doesn't help either.

[@acservicetechchannel]

If that is a concern, you could install FRAGs in the house. Filter return air grills and you just change the filters inside the building, thanks

[@MusicLuv80]

@@acservicetechchannel Thank you for the answer. But actually technicians came by after writing to you and they put lot of mastic duct sealant inside the filter rack top of the tapes that were covering the holes but also put lot of mastic duct sealant all over the inside the filter rack just to make sure no air leaks. Is that pretty safe to use inside the filter rack? and putting them top of the tapes.... Is it all good?

[@jmartin61]

It shocks me this most customer facing part of the assembly is custom crafted (and I use the term "crafted" generously based on the ones I have been stuck with) at the site and not a standardized component. This thing is supposed to be accessed every 1-3 months, so in very short order the "slide" is gone or at best replaced by duct tape.

[@acservicetechchannel]

Very true Jeff! The ones that are pre-made are typically for wider filters. These filter racks a lot of times will still fit a 1" filter with a rod that narrows the width of the rack and holds the filter upright. Anyway, that is why I put the video together, because I am stuck trying to get filters in spots where they don't want to go or come out. We used to use magnet covers before the pressurization testing came out. We would buy the magnet material from our local sign company, thanks!

[@Kilo5910420]

Please invest in some malco offset snips..those straight snips suck

[@88mmFlaK]

thanks for the vidya information status: increased

[@brandoncoldcall]

How the heck did you make the filter frame thing? Out of sheet metal and make into a frame?

[@acservicetechchannel]

With a sheet metal hand folding tool. They come in 12", 18", 24", thanks!

[@richardtuholsky4028]

Let’s go brandon 🍦🍦🍦

[@ilashandlove6726]

This is what I need. Mine is just wide open and the filters never fit real good.

[@brandonstump2375]

Snap lock punch?? Looks like a pair of notchers to me

[@acservicetechchannel]

Yeah, notchers are the hand tool that would cut that small triangle piece out at 1" long. Check out a google search on sheet metal notchers, thanks Brandon!

[@isotac7789]

Good video, but for the time and cost it makes more sense to buy a factor made filter rack. However, the key here for others viewing don't ignore the filter rack outside the furnace cabinet, manufacturers worth their spit do not want the filter inside the cabinet of the heater, nor should a homeowner put up with an installer who makes changing the filter a chore or impossible.

[@acservicetechchannel]

Thanks and with this method, you can cut a filter rack into an existing duct fairly quickly with the furnace blower door off. Thanks for your comment!

[@kenstein]

I agree, but in my case I am putting a mid static ducted unit that's shaped like a pancake with a 9x50in intake duct in a ceiling and want to avoid having a bump in the drop ceiling below the unit. So rather than using a standard 16x25 filter rack I can buy anywhere for 30 bucks I have to make my own to use two 10x24 filters side by side to make a 10x48 filter inside a custom plenum. So I found this video very helpful!

[@matt8863]

Nice job! Awright? lol

[@acservicetechchannel]

Yeah sorry, bad habit for videos. I use that in the classroom as an eye contact cue as I peer across the room at each student to make sure they understand what I am saying. It seems that it doesn't help me here for some reason, ha ha! Thanks for letting me know Matt8863

[@miketruitt8052]

With the terrible air-flow we get with 1" filters, why are we showing folks how to do this, as opposed to installing a better air-flow, low pressure drop 4" media filter?

[@n9wox]

Good question. I would like to learn how to convert 1" to a 2" or 4" filter frame.

[@jr1001jr]

That's why I came to this video... 4" Filter would be better for the system (from what I've read).

[@ilashandlove6726]

Maybe just make the hole bigger.

[@tzarius78]

@@ilashandlove6726 pretty much and the slide is installed already

[@wheelerdealer2105]

Why not make it 2 inches thick or more?

[@josephmacias8340]

Use offset snips..cuts much faster instead of switching snips back n forth

[@acservicetechchannel]

Thanks Joseph!

[@fortinosuarez7962]

Green is left, red is right.

[@acservicetechchannel]

Hey Fortino, green cuts circles to the right and red cuts circles to the left. You use both in the same dominant hand, thanks

[@lanesmith4422]

Just found this video, but no, no, no, no, no. Any tech that has done service will curse your existence for this filter rack. Give the future techs who have to pull a distorted filter at least a 4 inch wide opening, that way the wire reinforced media doesn’t get hung up in the narrow slot. Additionally check closely the filter sizing a typical 1 inch 20x20 throw away filter is only adequate for 2 tons of air before the initial resistance is too high for the system. And finally please step up your game and use a 2 inch or even a 4 inch filter. And before anyone comments that a 2 or 4 inch filter will have more resistance you need to study filter charts and gain a full understanding of air filters and how they work.

[@TheDeadheadable]

The filter goes on the return not the plenum

[@acservicetechchannel]

Hey Travis, this is on the return plenum, thanks

[@richardbianco3193]

Thanks. I'm a 50 year old retired IT guy and thinking of getting into one of the trades, just not sure which one is most needed in Florida, and what I enjoy. So far have tried Drywall, Painting, Tile (bathrooms), dabble in electrical and plumbing and now these videos. I don't really care how much money I make I just want to make more than a $100 a day that I'm making as laborer for a remodeler, and have fun of course, not kill myself. Any suggestions? Of course you don't know me but what trades are easy to get a job as an apprentice, or am I too old, I'm in good physical shape and smart enough to program computers. Thank you sir. IT is a burn out career and not a place for 50 year old, rather a 25 year old Indian.

[@rogermartin2176]

Sorry I meant U Channel

[@acservicetechchannel]

Usually you can buy it at the supply house but I just make my own 1 1/4" by 1" by 1 1/4" on a sheet metal brake. Thanks for the question!

[@100percentgradeA]

Kids these days ... Reds -right Green - left. Not the direction of cut, because you can cut both ways. But where you piece/ work is located vs waste.

[@JonathanDanielBowen]

After watching your video, I realize, now, that the guy who installed the HVAC in my home is an idiot… The filter rack is busted! He didn’t install any rivets so the filter rack is completely bent… He installed screws at the exact locations you warned against installing screws so the filters get torn to shreds on the way in and on the way out. The hole at one side of the plenum is a bit too thin for a filter so I’m assuming that he didn’t measure or, worse, test the hole or filter rack with a filter. He didn’t create a slide; I didn’t know slides were a thing but, now, they make complete sense… I’ve been thinking that I’ve been the problem for the past five years… Gah!

[@Alundrahs]

Zzzzz Zzzzz