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Nov 16, 2021 at 23:46 comment added AKG Got it! Thanks - I'll be back in two weeks or so to tell you how it went.
Nov 15, 2021 at 19:36 comment added JACK @AKG If the tabs hold the connectors securely to the plenum, then just use the AC mastic. The screws would only be needed if some of the tabs were missing or the connectors fit loosely into the plenum.
Nov 15, 2021 at 19:22 comment added AKG (b) reinstall the plenum under the house where it used to be (c) reattach new foil flexduct to the connectors. The black inside tube gets routed over the connector and held in place with AC foil tape. The insulation and foil layers get pulled over the black tubing and get held in place with tie strips. (d) Reattach the 16 in supply to the plenum, and the 16" return to its vent.
Nov 15, 2021 at 19:21 comment added AKG Thanks Jack. The plenum is (2) 10-ft sections that were joined with a sheet metal strip to make a 20 ft plenum. The house mover had yanked the flexduct + connectors free from the plenum, and then removed the plenum. I cut the connectors loose from the old flexduct and threw the flexduct away - it was pretty ragged. So, if I understand you, the job is: (a) insert the connectors back into the plenum, bend up the tabs to the inside surface, secure them with A/C mastic, sheet metal screws, and AC foil tape - to be continued.
Nov 14, 2021 at 0:38 comment added JACK Connector with tabs to plenum, use AC mastic. Connector to metal duct, use screws and AC foil tape
Nov 14, 2021 at 0:35 comment added JACK @AKG Was there a break between the connector and the 10' section? or did you cut the duct?
Nov 14, 2021 at 0:14 comment added AKG After thinking about it, I think the clever tool is a hand with a block of wood, reaching through the connector and mashing the tabs up. Should the connector be secured with sheet metal screws? Or just tape?
Nov 13, 2021 at 22:18 comment added JACK @AKG Have never seen a clever tool for this. You might have to cut the old connector off the duct, install a short one into the plenum and connect the duct to it. I'm surprised there's no break between the connector and duct.
Nov 13, 2021 at 21:37 comment added AKG This is very helpful, and makes sense - Thank you. One problem: how does one bend the tabs back up against the inside of the plenum when it is in two 10 ft. sections with the cutouts unreachable from the end? Is there some sort of clever tool that fits through the connector, expands to flatten the tabs, and then collapses so it can be drawn through the connector? BTW, its a crawl space, not an attic, but the advice about insulation is relevant.
Nov 12, 2021 at 18:51 history edited JACK CC BY-SA 4.0
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Nov 12, 2021 at 18:07 history answered JACK CC BY-SA 4.0