After work I set up my laser and used it to mark the sections for the HVAC supply and return ducting. I was a bit concerned about cutting into the vertical beam inside the building so I took my time and measured everything several times and then drilled a pilot hole to confirm the markings.
Once that was all done, I used a 4" (100mm) grinder with a thin disk metal cutting blade to zip through the metal. After that, I cut and installed some left over sheet metal angle to serve as a drip edge before pushing the ducting pieces through the holes and attaching them to the HVAC unit.
The cut edges turned out really accurate and left a 1/8" (3mm) gap all the way around the ducting which was really easy to seal up with some flashing caulk.
After that was done, I sealed up the edges with caulk and aluminum tape.
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| Marked sections of metal to be removed |
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| One section removed |
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| Inside view - supply and return straddles the vertical beam |
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| Just about ready to be attached to the HVAC unit |
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| All taped and caulked |
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| All taped and caulked |
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