How To: Fabricate A Plenum Box With BASIC Hand Tools | HVAC Ductwork

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Sheetmetal fabrication is a necessary skill in the HVAC trade. In this video I show how I custom fabricate a sheetmetal supply plenum for a Goodman air handler with basic hand tools (I'm using Malco tools). There are several ways to go about this process, this is just one way. A pro tip is using a window screen roller tool to create the cross brakes in each side of the plenum box. Hope you enjoy the video, LEST'S DO SOME WORK!!
#hvac #ductwork #sheetmetal

[@ACmanDean]

I have been in the Hvac business for 30 years on the repair/service/ installation side. Always had the sheet metal guys build plenums I needed. Well, for what ever the reason, they didnt like me very much and refused to teach me. So I invested in what tools I needed, similar to yours and began to learn on my own. Videos like these are a great aid to me. Thank you so much. I have been doing sheet metal on my own now for about 6 months. Your video has helped me.

[@isaiahbeanisaiahbean4525]

I'm 19 learning ang video u can recommend?

[@ethanrogers3968]

​@@isaiahbeanisaiahbean4525What would you like to know about sheet metal? I'm 20 and a 3rd yr apprentice. If you've got any questions let me know

[@mikejustice1196]

@@isaiahbeanisaiahbean4525sheet metal is fun. Sheet Metal Dude utube. He’s the best and very detailed and doesn’t skip a beat and there’s no BS with him and no sick music to listen to

[@JustFixIt99]

I would love to see this made into a series. Take each basic part of a solid duct system and show how to make it with basic tools.

[@brotheraugustine]

I second this

[@igotsomespace]

I second this

[@sorinankitt]

@@igotsomespace you mean 'third this' ! 🤣

[@fishandgameman]

I’d like to see this one made out of two pieces instead of four, sans the lid, only using hand tools. You would only have to make one bend with something other than the tools shown. I can think of several ways, but seeing it done would up confidence.

[@amiga2025]

i keep hearing S-slaw

[@briar4657]

Concise and to the point with 15 minutes and 53 seconds of useful information unlike the guys who bs for 10 minutes to make a 15 minute video with 5 minutes of useful information.

[@James1095]

Using the window screen tool to make the cross brakes is genius! I've had one of those tools hanging on my pegboard for years and it never occurred to me to use it for that. Lacking a large box & pan brake has been an obstacle but with that trick under my hat I hardly need one now.

[@robertlowrey5485]

always been kind of intimidated by metal stuff, this gave me a bit of confidence. I want to play around with some sheet metal now.

[@drudarby4269]

I made it all the way through the video then decided that I better google “what is a plenum box” 😂

[@edwardrebeaudiii9109]

Lol.. it’s all In the AIR

[@embracethesuck1041]

Hopefully you're getting smarter every day.

[@alonzocoston6552]

Same

[@EastDallasKicks]

@@embracethesuck1041 ?💀

[@supershiv209]

🤣🤣🤣

[@mikeerin5031]

These types of videos are the best ones. Teaching folks how to put things together and build ductwork at home. Keep up the great content.

[@picklerix6162]

Steve Lav has some pretty good sheet metal videos. He does a good job of creating sheet metal transitions to tie in the new furnace with the existing ductwork. For some reason, most of the HVAC contractors in my area love duct board but I’ve seen some real sloppy installations using that product.

[@andrejwalilko634]

thank you for jumping straight into it instead of a lot of hullabaloo at the beginning of the video :)

[@JCPaintGuy]

Awesome, step by step video! I’m about to make my own return plenum box, and this was super helpful. Thanks for taking the time to do this!!

[@mkestlz]

you tube is cool as hell. i've been a square duct / hvac layout and installer for over 30 years.I ve installed more than several hundred hvac systems. I worked with and was taught by several old men who were sheetmetal mechanic in the 60's. But none of them ever showed me about the screen roller to make a cross brake. I would of never thought of that. Thanks for sharing. Sheetmetal fabrication is becoming a lost art. I am trying to learn all of the old ways of sheetmetal fabrication, and (tinsmithing) . I'll definetly use the screen roller to put a cross brake on my tie ins next time I change out a unit and have to field fabricate the duct work. Thanks Again

[@DennisCrossSr]

I’m in need of a little duct work for my powder coating booth. Was going to google the pieces that i might need. And decided to watch a video. Thanks for your video. The screen roller i already have. Plus I’m retired and wanting to learn a lot more fabrication techniques. Keep up the great teaching job. You are a teacher. Easy to learn from you without any B/S. Teach ON. Thank you so much.

[@daveg8918]

Awesome work Zach. Makes people who are Not confident definitely more confident in doing that stuff.

[@5238117]

I love the great content on this channel! I’m not too field experienced but 22 years in the industry on the supply side. I had questions about a lot of things the contractor goes through daily. So through your channel I have a greater appreciation for the work that you do. Thanks R

[@boby115]

Love the tip on the screen roller to make cross brakes, great idea ( someone was thinking when they came up with that idea)👍🛠.

[@michaelmeans9187]

Excellent tutorial. Please keep up the good work. I greatly appreciate you taking the time to produce these videos.

[@W4AX]

Zach. One of your best videos yet. I learned some great tips. Thank you!

[@nelsonperez416]

I just made my own plenum box aided by this video and it turned out great. Very good video. I used a pizza cutter already at home for the cross breaks and it did the job perfectly. Thank you!

[@Meatwad.Baggins]

I was thinking about using a pizza cutter 😉

[@LovelessRanch]

Great idea! Probably leave that one out in the shop now…. Don’t think it will be great at cutting pizza anymore 😂

[@nated5166]

Man that's beautiful work! I'm in school for HVAC now and duct class is one of my favorite ones getting to be in the sheet metal shop and doing projects

[@richardthomas1743]

I found your channel a few weeks back. I have to say that I am enjoying it and am learning a lot. I think that you would make an excellent teacher. Thank you and thumbs UP to you. 👍

[@ramchillarege1658]

Great demo. I have never made these, and your video and crisp identifications of the key tips make this an excellent video. You are great tech and excellent instructor. -- Ram, an HVAC enthusiast. And budding retirement tech.

[@michaelbyron1166]

Excellent presentation and demonstration. I always wondered how you could form those cross breaks by hand. Thanks for the tip. I learned something new today.

[@djcampbell9150]

I recently installed a new furnace and had to rebuild the plenum between the furnace and A coil. This video was a huge help! Thanks

[@tygoulding2547]

This video helped a ton. Thanks man. With a little perseverance and help with people on KZbin you can do a lot.

[@gerardoortega4027]

When I was a kid, my Dad taught using thin cardboard and then used the 4ft brake to make the bends. I really enjoy it. We used to reconditioned swamp cooler and make new one from scratch - Nice video! thanks for sharing!

[@marcus2rell187]

I’m in school learning this now. We’re using the Pittsburgh machine for our 1” and using the drives and S cleats to connect everything. I’m definitely grabbing one of those cross break tools

[@davidgibson9781]

That roller idea will save tons of money and time. Thank you Zach!

[@repairitdontwreckit4257]

Nice job. Perfect instructions for someone with basic tools. Great tips.

[@shonhaines1995]

Awesome video. Very glad you are back and most importantly got through Covid!

[@zacharyloewke6366]

If you're not privy to the Hilti S-MS HHWH sheet metal screws, they are a serious game changer. Absolute beast for assembling ductwork. Once you use these, you'll never go back. They are more than worth the money.

[@user-lk4xy1kp5h]

I just made a supply plenum just like yours but different dimensions. It came out awesome. Thank you for your teaching time.

[@frank9301]

Great job! I've done this serveral times myself! Love the screen tool idea! I'm going to pick that up. Thanks for making the video!

[@sergeyakimov7332]

Thanks why appreciate working with old heads.. they might be grumpy but you can learn a thing or two..learned all these tricks working side by side with so amazing guys

[@utubepro7742]

Great tip on Roos hatch I’ve tried soo many things but can’t wait to use that tool Thanks!

[@erep4537]

great video with great directions. Exactly the way I have been making plenums in the field... awesome job

[@starhopper457]

"Let's do some work!"... refreshing to see a solid work ethic from this young gent. Well done, and inspiring. I need to do some work myself to modify some of the ductwork on my A/C. Kudos Sir!

[@lafonpancho9842]

Great job Zack. Thank you so much for that class. Respect from NYC.

[@k.sullivan6303]

That's a nIce job! As others sometimes do, I also make a safety edge on the bottom flange. Another thing that can be done, is instead of using S cleat for the seams, you can make your own Pittsburg Locks which look far better and more rigid. The Pittsburg locks take quite a bit more time by hand though. Many guys in the field would just use the S locks as you did, but if the job was a big profit job, or for your mother or father you might spend the extra 30 minutes to an hour making those Pittsburgs. WIth good handtools and experience at it, those Pittsburgs might only take an extra 10 or 15 minutes. You have a good long bar folder on hand there I see! That helps. One thing I learned here was using that wheel to make the cross braces...very cool.

[@wilianaldanadiaz7086]

You just save my life literally The old house that we live in does not have a register/supply box for our furnace Thank you so much

[@michaelroach8607]

I found saving my cardboard underneath my sheet metal helps make the cross breaks.

[@robwilson782]

I'm not a tradesman, just a handy home owner and I was look to make a drain pan. Your video was my next youtube suggestion. I'm not even sure what that's used for, but it's a thing of beauty and I enjoyed watching you make it. Thanks.

[@irishhandyman2009]

Thanks for sharing. The screen tool trick is great. Big help for me right now. Great explanation on how to assemble.

[@bobboscarato1313]

Great work particularly out in the field away from machinery!

[@aliposhtpazan2625]

God bless you for showing us how it is done with some easy hand tools. Many thanks

[@tomsmith3045]

Really nice work. It's cool to see tips from people that know their trades well.

[@chicagomike6666]

nice video! Really instructive on how to use basic tools to produce a really solid product!

[@advancedbasher]

First time seeing how to do sheet metal .. you made that look easy!.. Great Job I would like to see more with the basic tools also .😁

[@captainmonzi9472]

GREAT JOB! Nothing like KZbinU! Thank you Professor HVAC! Had an A/C guy install a new system for me and they had the plenum built out of rigid insulation…. New system blew apart the crappy plenum. Thanks to your very well dont video I’m going to make a sheet metal plenum tomorrow. You are the first “subscribe” I’ve ever done! Now I just have to look for a video on how to attach the flexible ductwork to it and I’m golden!

[@all-starservice6007]

Sounds more like your new system is 6 sizes too big.

[@robertotorres1081]

Thank you for taking the time to teach us.

[@Dave-nm3xc]

Thanks for this video. I know absolutely nothing about HVAC, so its fascinating to see how its done.

[@BruceLeanTrades]

i do new construction and we have a shop guy who builds all of our plenums, transitions, mixing boxes etc but it’s still nice to learn so one day when i’m out on my own i’ll be good to go lol

[@mercerino]

Awesome and concise. Super helpful. I have one simple 24x36x12 plenum to building and didn't want to get an HVAC outfit in just to build that.

[@paramparmar8847]

Can you please do more sheet metal videos specifically where you made transition while changing units like furnaces

[@jesusm1089]

Excellent video! You made it so easy. Thank you very much for sharing!!

[@Comm0ut]

Great stuff! I'm competent at most DIY but only did my own car/truck AC work. Your vids will help me add heat pumps to my workshops. Liked and Subscribed!

[@aaronbillings3250]

Nicely done I am putting in a furnace for my daughter and I am going to follow this procedure but with the first guy's 3/8 bend underneath safety flange and I will be add gasket material thanks alot very helpful 👍

[@Wrighmachining]

Hey thanks man , used your video . I just rebuilt my plenum box above my furnace to add in a new ac coil. With a back ground in machining but no exp in sheet metal it was a snap with this videos . It was just like grade 2 all over again cutting out paper shaped and glueing them togeather except the paper will cut you bone deep and the glue is s clips and c clips

[@gc8836]

Great video. Need more like these I'm always looking for way to improve my installs. I'm work in Dallas Tx and all I get my hands are flex and fabricated plenum's in residential.

[@m.montgomery6835]

This is the best one I have ever seen. Thank you!

[@tomrunning357]

Almost cruised by your video, but it turned out to be very informative and easy to follow. Plenums are not standard in size and this is just what I needed to to make mine. Thanks!

[@toad7671]

Tryna learn more , 17 and been in it for the past 3 months , helping us out

[@stevencarrillo3615]

Really like how you showed how you did it and you made look easy thanks

[@trunkshvac3339]

Nice looking plenum sir. Always nice to see another man's process. I've been blessed for the last year and a half to have a little malco 4ft break, man what a life saver. Save me from those insufferable cut down plenums that cost you a pound of flesh. But I think that to really appreciate a nice tool like a break, you gotta know how to do all your sheet metal work with hand tools. Just my thought. Nice trick with the cross breaking too. Never saw that trick... thanks again!

[@RaySteady]

If you have a four foot brake I’d suggest folding your own Pittsburghs on the flat stock instead of spending money on S locks to connect four sides.

[@inqwit1]

Nice. I appreciate the fabrication guys I use occasionately ever more highly. And,..., I am going to follow your lead and build one for fun. Tahnks.

[@netsplit64]

Thanks to this video I built a very nice and solid plenum!

[@yippeethreeeight]

Fantastic video! My installer screwed up my ductwork, and is dragging his feet to come and fix it. I've called other companies, and it's too small a job for them to be interested in, so I've decided to try to fix it myself. This video is exactly what I need to do it.

[@TheModelmaker123]

This was a very helpful video. I got a little aggravated with commenters saying this could have been done with one piece of metal. Sure it could have, but how many DIY's have a 4' metal brake to make the bends. This video showed how to make the plenum with basically common hand tools .. and the 2 foot hand bender. It sure boosted my knowledge for dealing with sheet metal. Thanks

[@DevonBurgess]

This can be done with one piece of metal and no brake as well. If you notch each corner top and bottom of the plenum prior to bending, you can easily bend this up in one piece.Line the edge of your folding bar up with your notches Put a c-clamp or some locking pliers on each end so it doesn’t move, and bend away. OP’s way may be easier, but it’s more labor and material intensive. Try not to get aggravated next time. Some of these people are just trying to educate. Sorry if my explanation was hard to follow, everything is a little easier to teach in person/video.. 😅

[@rogerf3622]

Great video. Clear and concise.

[@tdnguy3n]

Subscribed. This vid is very helpful for me as a newbie in ductworks.

[@nolanharris640]

That’s a good tip on the screen roller going to add one to my tin box

[@fighkb]

The screen tool 🤔 that is an awesome idea 💡 thanks for sharing, good job 👏 nice video.

[@GB-ue6wr]

Clean can Zach.. nice tip on the roller for the cross break!

[@michaelfassino4314]

Absolutely perfect instructional video !!!

[@richardkirts4007]

Great video. Really great tip on the cross brace. Thanks

[@docholliday45lc3]

Gotta say I do hvac for a living and was very intrigued by how you did this, I’ve been blessed recently with a brake and a Pittsburg, both of which I’m still getting used to as they are old and have their own tricks, this is a very nice job almost a shame to bubble wrap it.

[@solideogloria7987]

Those are 2 of my favorite things to use, do you layout, crossbreak, pittsburgh, bend your flanges, and then bend the 1/4 and the other half of the plenum and you'll be golden.😎👍

[@toad7671]

You bought your own Pittsburgh machine ? :0

[@SnipFishFab]

KZbin didn’t exist when I started . Good on you for teaching 🙏🏽🤘🏽

[@dennishala1272]

Ur a great teacher. After seeing this I would snap a chalkline corner to corner and that would be my line for the ❌ to roll it out. I'm creative like that

[@kevynpham]

Very professional ,very detailed ...I wish you in my town.Thanks for a video

[@heaappraiser4060]

Great job, and nice how-to tutorial!

[@condorman26]

Nicely done. Only thing I'd do different is the 1" flange that rest on top the air handler. I would have used your folding bar with the 3/8 side to bend it under itself. Making it a half inch double hemmed safety flange. No sharp edges that way.

[@k.sullivan6303]

I was gonna mention the safety edge too.

[@mikeerin5031]

Great idea!

[@donniehallaman7685]

Good point , I just now screw straight into the flanges in the ah, now a days you gotta tape, mastic , duct seal or whatever method you use and wrap it anyways, kinda mitigates the sharp edge thing, of course tho some stuff is exposed and not wrapped then 100% the double half inch hem, flange , whatever is the safest and of course best looking no doubt 😉

[@The_Humble_Servant]

@@donniehallaman7685 you guys have to wrap in non-humid basements?

[@donniehallaman7685]

@@The_Humble_Servant yea we have to wrap anything that isn't conditioned space, if it was exposed in say a finished basement with runs then no. But if it's unfinished unconditioned space then yes

[@HVACingMyWay]

Thanks for the tip I have the Malco 4 ft break but I can’t always bring it with me been looking for a way to break it makes it look so much better and stronger

[@r.sanchez-vazquez274]

Looks good! i cant wait to build my own. thanks for the video

[@veteranjeeper1120]

Great video, you should make a video on your install bag what bag you're using and how you organize everything. I'm always looking curious how other techs are doing things in the field, 20 years in and I'm still trying to learn and get different ideas

[@brianphillips4115]

love the screen roller or pizza cutter idea for your cross break, genius

[@wolfman7393]

You made it easy and clear! Thanks

[@TheSociologyOfCharlie]

Thank you! My first came out perfect because of this video.

[@TheBoxFort759]

Great video, great explaining every thing.

[@JohnnyUmphress]

Fantastic tip using a screen tool to crimp an X brace. Thanks.

[@The-H-inADHD]

Great job brother! Sheet metal work is something I would like to get good at.

[@bobboscarato1313]

Usually takes talent; watch out those power brakes; I knew a guy who lost his 8 fingers; he was all thumbs!

[@scottyates8783]

Great 👍 job Zach plenum looks great

[@jonstivers]

Great video. I found another one where the mechanic builds a one piece plenum using the edge of an aluminum step ladder as a brake. Both ways are good, one piece is less expensive, uses fewer s Locks. Thank you.

[@all-starservice6007]

Its not a lock, Its an S-Cleat. S-cleats are used if you're too lazy and stupid to make a lock.

[@ryzlot]

Great video - very talented JR

[@happybearinc.9083]

Very good video and helpful to learn how to fabricate a plenum box in the job site

[@rageofsaturn]

As someone who's fairly new to the feild I appreciate you teaching the sheetmetal side of this. It's not something I have much experience with most of the plenums and hard duct usually comes in 3 pieces the "L" shaped sides and the end cap but this? I'll show the guys up one of these days at the install. Thanks for the content brother

[@flacojacobo5672]

Thank you for the time that you take to make this video you are a........ beast 💪👍

[@brandonneims9397]

That is F-ing beautiful work of art thank you I will use that knowledge to the best of my ability

[@BladDaddy]

Just what I was looking for. Good stuff.

[@electricalron]

Great video man. That's some really good, clean work.

[@warenmann1042]

Excellent job, I learned somthing I can use today. Thank You...

[@ericcrevling3759]

Yes love these videos! Definitely do more ductwork how tos.

[@dantemariscal8679]

Agreed. I don’t know anything about ductwork or sheet metal work

[@redneckgoatfarmer]

DIY guy here. 👍 Learning tins from your vids.