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Assemble the steel ducting like a zipper

When assembling pipe, begin at one finish and work the seam collectively like a zipper. Use one hand to maintain the 2 edges shut and the opposite to use downward strain. Use your leg, a workbench or the bottom to assist the again facet of the pipe. In the event you make a mistake and should dismantle a pipe, slam it down flat on the bottom, seam facet up. It ought to pop proper aside.

Dont peel off outdated tape of steel ducting

If it’s a must to disassemble current ductwork fittings, there’s no must peel off the outdated foil tape first. As an alternative, simply rating the tape on the seam with a utility knife and take away the screws proper by the tape. When it comes time to retape, simply clear off the mud and apply new tape proper over the outdated.

Step by Step Information to Chopping The Ductwork

Now that we’ve gone over the fundamentals it’s time to get into the main points. Earlier than even trying to chop ductwork, we should make preparations.

So let’s get into the dirty particulars!

Step 1: Security First!

Utilizing an angle grinder generates a whole lot of sparks and particles. So, it’s important so that you can observe these safety tips when using power tools.

All the time put on security glasses and a face protect to guard your face and eyes. It’s smart to put on ear-muffs or earplugs to cushion the grinder’s deafening sound.

When utilizing an angle grinder there’s a potential fireplace hazard. This is the reason you need to put on fire-resistant sleeves or jackets. Don’t overlook to put on heat-resistant gloves too.

In the event you’re uncertain about which gloves to put money into, check out our picks beneath:

Glove 1
Glove 2 

Now that you just’ve put your gloves on, you’ll be able to transfer onto the following step.

Step 2: Provoke Check Run on Angle Grinder

Inspecting your angle grinder is among the steps you’ll be able to’t ignore. Ensuring your instrument is totally useful will scale back the speed of accidents.

First, be certain that the grinder just isn’t linked to an influence supply. After unplugging it, be certain that the twine doesn’t have any frays.

Subsequent, examine the guard of the grinder together with its deal with. Make sure that the guard can transfer freely and the deal with is sturdy.

Transfer on to checking the slicing disks. Be careful for any cracks or knicks as they could trigger the disk to shatter.

After you’ve checked all of the parts, run the grinder at a distance. Run for not less than 5-10 seconds to see if the whole lot goes easily. Search for any wobbles within the disk and reinstall if it wobbles.

Now, we transfer to the following step, slicing the ductwork.

Step 3: Begin Chopping the Ductwork

The slicing wheel has a 4 and a half-inch diameter and is ideal for slicing skinny metals. The utmost thickness this wheel can reduce is ¼ of an inch thick.

For sheets thicker than this, use a plasma cutter. You too can use a Dremel to cut ductwork as it will possibly reduce by ½ inch thick bolts.

After you’ve secured the piece onto the work floor, you might start slicing. Lower in straight strains as twisting and turning could trigger the wheel to disintegrate.

When your wheel begins to jerk, flip off the ability change. Await the disk to cease rotating and pull it again. In case your wheel will get jammed, twist and break the wheel to take it out.

Now, we transfer onto the ultimate step which is the ending touches.

Step 4: Sand and Polish the Ductwork

This can be a step that’s largely ignored. That’s you could at all times sand out the tough edges.

For this, it’s a must to set up a velcro pad and sand-paper (220 Grit) to begin sanding. End off by putting in the sharpening disk for a shiny end.

That is how you chop ductwork with an angle grinder. We hope this put up was useful in studying the know-hows about angle grinders.


For this course of there’s a want of few components, amongst them first you’ll require a snap-lock pipe, that is the duct you wish to trim, subsequent you’ll require a tape measure, this may assist you to have a correct measurement whereas slicing, and after that, you’ll require a marker for marking the sizes. Additionally, you will must have snips which might be used to scale back, and lastly, to crimp the duct, you have to a five-blade crimper.


Mark the reduce line or space on sheet steel with a felt-tip marker. Punch a starter gap within the steel with the blade of a straight screwdriver and a hammer, massive sufficient to suit the tip of the compound snips inside. Lower from the opening to the road, then reduce the road round a spherical duct or alongside the circle or rectangle opening on a flat duct.


Lower flex duct with a utility knife or shears and tin snips. Slice the metallic outer layer and the insulation across the spherical flex duct with the knife or shears and lay it again to reveal the coiled wires. Lower every wire with snips, taking care to make the cuts even so the reduce finish is straight.

Issues You Will Want

  • Tin snips, a number of choices

  • Felt-tip marker

  • Hack noticed (non-obligatory)

  • Utility knife

  • Shears

Warning Put on gloves when slicing ducts, recommends Good Residence HVAC Design. Sheet steel edges are sharp and can reduce palms and fingers, and reduce coil wires can also injure. Lower ducts on a flat, strong work floor. Do not attempt to reduce ducts which are mounted to partitions or ceilings except you might be an skilled metalworker.


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