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.
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.
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.
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
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.
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!
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.
We are working on this type of work in class right now. I made a seamless drain pan today. Thanks for the tips Zac. I'm pretty sure making a plenum box is one of our finals this semester.
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
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.. 😅
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.
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.😎👍
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.
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 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
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.
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
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
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
One example where a DIY homeowner might find this process useful is connecting a replacement downdraft cooktop to an existing ductwork to outside. I fiddled with fittings and adapters for two days but there just wasn’t room inside the cabinet. The solution- a small plenum box built exactly as you describe here with a cutout for the fan unit on top and another cutout for the round existing exit duct on the bottom. All the parts you use are available at a nearby home center. If I had anything to ask you to add it would be the materials used to seal the box during installation.
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.
I'm not in the HVAC trade, so I had never seen one of those bending bars. Had to watch the rest of the video to see if there was any other life changing tools I wasn't aware of.
The best way to make cross breaks in the field is a henslers bender, i made one myself and can crossbreak a piece of metal in 15 seconds. I fabricate transitions everyday, the tool is a must.
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!
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.
@@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
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 👍
Was watching the furnace installer and was perplexed by crossbreaks. I looked away for a moment, and he was finished. I was like, I missed it? So I asked HTF did you do that? A bit hesitantly he grinned and showed how he scored it - awesome.
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.
@@josel.guerrero2658 1-Draw a circle 2- Drive a stout flathead screwdriver through the metal with a hammer 🔨 3- Drive the head of the screwdriver 🪛sideways through the metal until you have a 4"-5" gash torn into it 4- Use offset snips to cut out your circle 5- If your hole is too small, trim it 6- If your hole is too big, discover metal patches and pookie🤣
I always used adjustable quick scribes to mark the notches. I have never seen that cross break tool before . I'm sure it would only work on 26 ga. metal or lighter , but seems make a nice looking break .
I just built one of these per the video and it turned out great--the only thing I did differently was the "safety flange" that condorman3 described in this comment thread. I even had one of those screen window installation tools in the shop and didn't really know what it was until this...🙃
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
great video..keep them coming...I will say though not everyone going to have that size folding bar so you should give other options on how to do something..never saw a cross brace done like that it was Sharpe I normally bend then on a table but there normally round..but just different option..did you end up duct dealing that plenum super important then of course you have to wrap it..
I'm a 33 year HVAC guy with a full bag with tongs, Whitney punch, bar folders, tongs, tinner hammer, panduit gun etc etc etc, and while I CAN build a box, I do every 9 years. In my opinion there are very rare boxes or ducts what are well done, and none that are as good as a fab shop. Good Pittsburgh's, furnace flanges. shoes etc mean that a fab shop with do a more professional job than a field setting 100% of the time. I can't count the boxes I've seen built with S locks. It is rare that I have to build a plenum on the fly. It's an installation environment which mean, and should imo, plan. So 99.99% of my jobs are planned and executed well through planning, which means things are fabbed.
You are absolutely right a properly measured and pre fabricated plenum is ideal however he did a pretty solid job considering only hand tools. totally useful for on the job application
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.
I second this
I second this
@@igotsomespace you mean 'third this' ! 🤣
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.
i keep hearing S-slaw
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.
BAS technician here, installing my home A/C project. Watched tin knockers for years, but never really paid attention. Good tutorial, thank you!
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.
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
Pros make it look easy. Back to my day job.
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.
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.
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!
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.
Awesome work Zach. Makes people who are Not confident definitely more confident in doing that stuff.
Love the tip on the screen roller to make cross brakes, great idea ( someone was thinking when they came up with that idea)👍🛠.
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
We are working on this type of work in class right now. I made a seamless drain pan today. Thanks for the tips Zac. I'm pretty sure making a plenum box is one of our finals this semester.
Which school do you attend if you don’t mind me asking?
@@markanthonyrogel8221 it's a technical college in Kentucky.
@@b-2466 is Herman your teacher ?
I tried making a seamless pan just could not pull it off. Not sure what I was doing wrong.
@@daveg8918 no, don't know any herman. Mine is Keithen.
THANK YOU! Greatly appreciate the minimal approach taken with hand tools and ready to tackle my first custom transition (in Philly).
I found saving my cardboard underneath my sheet metal helps make the cross breaks.
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
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.. 😅
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.
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.😎👍
You bought your own Pittsburgh machine ? :0
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.
I was gonna mention the safety edge too.
Great idea!
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 😉
@@donniehallaman7685 you guys have to wrap in non-humid basements?
@@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
This video helped a ton. Thanks man. With a little perseverance and help with people on UA-cam you can do a lot.
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.
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
Zach. One of your best videos yet. I learned some great tips. Thank you!
UA-cam didn’t exist when I started .
Good on you for teaching 🙏🏽🤘🏽
Thanks for this video. I know absolutely nothing about HVAC, so its fascinating to see how its done.
Crazy how well the cross breaks turned out
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
DIY guy here. 👍 Learning tins from your vids.
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
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.
Can you please do more sheet metal videos specifically where you made transition while changing units like furnaces
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 .😁
love the screen roller or pizza cutter idea for your cross break, genius
One example where a DIY homeowner might find this process useful is connecting a replacement downdraft cooktop to an existing ductwork to outside. I fiddled with fittings and adapters for two days but there just wasn’t room inside the cabinet.
The solution- a small plenum box built exactly as you describe here with a cutout for the fan unit on top and another cutout for the round existing exit duct on the bottom.
All the parts you use are available at a nearby home center. If I had anything to ask you to add it would be the materials used to seal the box during installation.
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.
that little roller a damn good idea for a cross brake.
Great work particularly out in the field away from machinery!
That was very easy and simple sir thank you
I'm not in the HVAC trade, so I had never seen one of those bending bars. Had to watch the rest of the video to see if there was any other life changing tools I wasn't aware of.
The best way to make cross breaks in the field is a henslers bender, i made one myself and can crossbreak a piece of metal in 15 seconds. I fabricate transitions everyday, the tool is a must.
I made it all the way through the video then decided that I better google “what is a plenum box” 😂
Lol.. it’s all In the AIR
Hopefully you're getting smarter every day.
Same
@@embracethesuck1041 ?💀
🤣🤣🤣
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!
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.
I just ordered a roller, that’s fucking sick. Besides my journeyman, you’re the only guy I’ve ever seen cross break plenum panels lol
I’m getting a roller ASAP. I’ve been using a flat head screwdriver with the Barfold to score the cross breaks for years. This looks easier and cleaner
Yeah for sure we have been doing that stuff all wrong.
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.
I'm 19 learning ang video u can recommend?
@@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
@@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
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 👍
You can also do the cross break over the cardboard box that the furnace or other materials came in.
Nice video.
Go to harbor freight and get their 3' brake with stand, about 250 bucks. Worth every penny and have used it for years!!!
Sweet got a new furnace installed and need a plenum. Even easier than autobody 😆 all I need is a folding tool. Screen tool was awesome idea
Great tip on Roos hatch
I’ve tried soo many things but can’t wait to use that tool
Thanks!
Fantastic tip using a screen tool to crimp an X brace. Thanks.
Really know what you're doing some good pointers thanks
Was watching the furnace installer and was perplexed by crossbreaks. I looked away for a moment, and he was finished. I was like, I missed it? So I asked HTF did you do that? A bit hesitantly he grinned and showed how he scored it - awesome.
A Phillips Screwdriver will work also.
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.
Its not a lock, Its an S-Cleat. S-cleats are used if you're too lazy and stupid to make a lock.
Thanks for the video! ... For anyone searching for "folding bar" it is the Malco 24" hand bender (last item in the list of tools).
Question how to put the holes (exits)on the plenum box?
@@josel.guerrero2658 1-Draw a circle
2- Drive a stout flathead screwdriver through the metal with a hammer 🔨
3- Drive the head of the screwdriver 🪛sideways through the metal until you have a 4"-5" gash torn into it
4- Use offset snips to cut out your circle
5- If your hole is too small, trim it
6- If your hole is too big, discover metal patches and pookie🤣
One craft closer to making my spaceship. Thanks
Really nice work. It's cool to see tips from people that know their trades well.
Very professional ,very detailed ...I wish you in my town.Thanks for a video
Awesome video. Very glad you are back and most importantly got through Covid!
Subscribed. This vid is very helpful for me as a newbie in ductworks.
You can also use the bevel end of your screen roller to open your s lock.
I always used adjustable quick scribes to mark the notches. I have never seen that cross break tool before . I'm sure it would only work on 26 ga. metal or lighter , but seems make a nice looking break .
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!!
Thank you for the time that you take to make this video you are a........ beast 💪👍
Very Good and seems easy but I'll practice Thank You
This video was super helpful! Thank you! 🙂
Thank you very much! Learning a lot.
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!
I like that roller for cross breaks, I always used a thick screw driver which works, but the roller is a much better way to do it.
This is the best one I have ever seen. Thank you!
Really like your hand brake. Great idea.
I was looking for something ales,
I found your video, THANKS
It is good
Great video man. That's some really good, clean work.
I just built one of these per the video and it turned out great--the only thing I did differently was the "safety flange" that condorman3 described in this comment thread. I even had one of those screen window installation tools in the shop and didn't really know what it was until this...🙃
The roller tool makes a nice clean job I will have to get me one of them
Very good video and helpful to learn how to fabricate a plenum box in the job site
Wow great job, very good video. I can do that, after seeing your excellent video, thank you for the schooling
Only with the title you made me subscribe thank you
Clean work man. Nice.
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
Very helpful and informative
Excellent video! You made it so easy. Thank you very much for sharing!!
Great build and tips
Beautiful work!
I'm still doing theory in class great job zac
Very neat 100% , would have love to see you making locks on the sides
Nice job. Perfect instructions for someone with basic tools. Great tips.
Great video. Really great tip on the cross brace. Thanks
Excellent video.
Thank you.
Yes love these videos! Definitely do more ductwork how tos.
Agreed. I don’t know anything about ductwork or sheet metal work
Very interesting. Nice work sir
Perfect timing! I just bought a used heater to use in the garage. This looks simple and easy to make. Thanks
This is sooo clean
Great video. Would love to see more sheet metal vids. For us service techs!
Smooth job dude very good 👍
hey my friend we are in similar industries... great video
great video..keep them coming...I will say though not everyone going to have that size folding bar so you should give other options on how to do something..never saw a cross brace done like that it was Sharpe I normally bend then on a table but there normally round..but just different option..did you end up duct dealing that plenum super important then of course you have to wrap it..
Nice job looks easy and fast.
I'm a 33 year HVAC guy with a full bag with tongs, Whitney punch, bar folders, tongs, tinner hammer, panduit gun etc etc etc, and while I CAN build a box, I do every 9 years. In my opinion there are very rare boxes or ducts what are well done, and none that are as good as a fab shop. Good Pittsburgh's, furnace flanges. shoes etc mean that a fab shop with do a more professional job than a field setting 100% of the time. I can't count the boxes I've seen built with S locks. It is rare that I have to build a plenum on the fly. It's an installation environment which mean, and should imo, plan. So 99.99% of my jobs are planned and executed well through planning, which means things are fabbed.
You are absolutely right a properly measured and pre fabricated plenum is ideal however he did a pretty solid job considering only hand tools. totally useful for on the job application
@@stevetranchida7610 I can't disagree with that.
Thank you so much. All this year's . Building plenums, never knew this tool existed. Lol, i like your shirt by the way, where did you get it?