Cutting openings in sheet metal ducts.

BETA-32 · 2007-10-22T00:41:31+00:00

I need to cut 2 rectangular openings in an existing HVAC supply and return ducts.How can I do this?I've tried using a power jigsaw with a metal cutting blade -- big mess.I see things like power shears when I do Google searches, but that seems like a whole lot of money to spend to just cut the 2 openings.Are there any hand tools or cutting chisels that will work for this?Any other suggestions?

Oct 22, 2007 23 Replies

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PaPaPeng 18 years ago

Visited the HVAC parts supplies shop recently. Saw a strange 12 inch screwdriver like tool that has a sharpened V shaped notch just behind the 1/2 inch blade. So I asked what for and how does one use this tool?

The tool is used to cut openings, straight lined or curved, in HVAC sheet metal ducts. Use the front of the blade to punch a slot hole into the metal. Hook the notch over the sheet metal. Hammer on the flat of the screwdrivers's shaft just behind the notched part. The notch will cut cleanly along the path of the blows.

Ingeneous!

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wingnut 18 years ago

Yes there are hand tools for this.

Why are you doing this?

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a 18 years ago

Tin snips.

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BETA-32 18 years ago

To provide heat and AC to a basement. The basement currently has supply and return ducts running across the ceiling, but there are no supply vents or return vents.

I just did the tin snips routine today and it worked without too much trouble. I also did what someone else here suggested and folded back a tab of the sheet metal on each end to create a double thickness and make the opening more rigid. That worked well too.

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