The HVAC crew that installed my new furnace last week did as others have
described here. Used a hammered cutter to make a simple slit in the sheet
metal, then used offset tin snips (they'll save your hands a lot of cuts) to
make the rectangular opening.
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
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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