DIY - bending air conditioning ductwork

[Vern2]

I had a bid for $7,000, plus for a 2 ton Ream air heat pump, no heat strips please. It's for my 400 square foot shop. A couple of things. I think 2 tons is too big. Another, I found this unit http://www.budgetheating.com/1_5_ton...1_p/129015.htm I do all my own electrical, so you can see there's some money to be made here.

I found this pan and box break at HF. http://www.harborfreight.com/36-inch...and-91012.html It's on sale for $176.99. Don't ask me, it's a long story, but I'm going to pick it up for $69.99. I need to make some metal drawers for a new work bench, and now ductwork for air in the closet shop.

What I need to know is what is an easy, simple way to build rectangle duct, register opening, and build my own filter jack for a slide in 24"x24" filter on the bottom of air handler? This is probably simpler then most of your home projects, but none of us is born with the knowledge.
Thank you for reading.

[Lu47Dan]

Vern, I hate to tell you this but the easiest way to bend up duct work is to buy the correct sized duct work, then modify it to fit your needs.
I have gone round and round with several people wanting to add duct work to a furnace for their shops and it always ends up a nicer looking job to buy the duct work and then modify it to fit where you need it to fit.
Buying sheet and trying to make your own might seem to be the cheaper route but the last time I priced everything out for a friend the sheet stock was over 50% of the total price of the job. Making it yourself takes lots of time, buying standard duct work saves a lot of time and frustration.
I work will tin-knockers at my regular job and have picked up some of their tricks, I have learned to hand flange for drives and can figure out most of connections used in ductwork.
You need to buy a few tools to do it either way, a hand flanger is the most used after a pair of good tin snips.
It comes down to, "Why re-invent the wheel?"
You can buy different sizes of duct work at most plumbing and heating retailers, that is what I do now when confronted with installing a furnace into an home shop.
And remember A/C ductwork needs to be insulated to prevent condensation from forming on the bare metal. The commercial bubble wrap type of insulation works well for that.
JMLO. Dan

[LW Hiway]

http://www.ductworkinstallation.com/...6/Default.aspx

One of hundreds of sites that will offer you information.

I kinda wanna agree with Dan with respect to your query.

While it is not impossible for you to self-learn how to make boxed type duct work, it is fairly critical in having some expertise in making it solid, insulated, and leak free.

Seam rollers, benders and a myriad of hand tools would possibly be needed.

FWIW, I have a few rooms in my shops that are at or a little less than the size you have wants to cool and heat and have found that window units suit me just fine. Of course, YMMV.

[Vern2]

It was to good to be true $69, it cost $129.90. The 36" break.

Lu47Dan,
I don't think I'm re-inventing the wheel. Sorry, I think wrong analogy. Some things cost me more money (not many), but their is no pride in having others do it for you. There is one thing you need to know about building a wheel, the radius. So that's what I was asking, what do I need to know when building a duct, register, jack. I totally agree that there are cheaper ways of doing things. But that may involve, not buying that tool you've always wanted. That's a good idea you gave me about buying the duct, I will. Thank you! I built my own house. No house payment at age of 30. I bought the duct and framed and insulated them myself. They came in two "L" shaped panels I hammered together. The 5 ton Heat pump (2200 square foot house) I had installed, so I did not have to build the filter jack myself. I'm sure you agree that $7,000 can be greatly reduced. I'll buy the ductwork, I only have about 41" to build straight duct to machine room. Then 12" long duct in same room with register, plus the filter jack. The shop is basically in my house. My wife questions me about the tools I buy. I'm sure all of you guys have been there. Now If she sees me using that tool ... "Good thing you bought that dear."

LW Hiway,
Thanks for the link. I'd been using google but hadn't come up with the right search words.

Seam rollers, Hay! How much is that!

Can't use a window unit, no windows. I have a 8' 7' tall remote controlled insulated door. Plus two man doors.

Just added this page to web site.http://www.enichesoftware.com/shop/heat%20pump.htm

[Walker]

Where in Az are you? I buy all A/C related stuff ay Webb wholesale supply. If you need, and are close I can go there with you to buy under my license. I would buy the round spiral duct and fittings, makes for really simple good looking work. Jacks, vents, etc, are dirt cheap, just buy 'em and spend your time making your own brake instead. PM me if you want to go to Webb.

[Vern2]

Walker,
I'm at Ray Rd and Gilbert, in Gilbert. My wife thinks were're poor. So I can't spend a thing til next May. Her's a knuckle head. I've got boxes of stuff around here now. I'm adding 4 shelves to try to hold the stuff, to figure out what I have. Finally got a rotary table 6". Will finish shelving tonight, Wife did all the welding last night. Just have the 3/4 plywood to cut. I made a big mistake, I tough her how to weld she's a natural. Honey can I use the welder...

I do not BS!!! She ran out of gas while meg welding. She just kept on going. I couldn't believe it. The weld still looked good. I have a new type of welder. It weighs 55lbs 110/220v inverter 180 amp (miller passport). It holds paint ball Co2 cans for gas. It will run for 25 min or weld 25 feet on a 12 oz can. It replaced both my Lincoln SP175 plus and SP135 plus welders. They left by way of Crigs list. Check it out http://www.millerwelds.com/products/...ash/video.html

[mccutter]

Originally Posted by Vern2

Can't use a window unit, no windows.

Who said you needed a window? Just make a "hole" to fit one of them--a brand-new "Energy Star" 15,000 BTU unit running on 220V ought to do just fine. About $300 rated for 1000sf. Make the opening a little bit oversize in case you want to move up in size. That is also 2ton territory assuming your shop has higher ceilings than a house.

[Vern2]

Walker,
I could have a field day in a place like that. I could make it look like a restaurant, bar, coffee house with round ceiling ducts, track lighting. For really not that much money (short runs). I almost put a 1/4 mile of 12-2/gnd in the house I built over 35 years ago. I'm still living there. Started the foundation in 1969.

mccutter,
Their's no pride in installing a window unit. It's a very simple install. I want air handler round metal duct, a remote (condenser). Something I can just leave on all summer and when it gets to 50 degrees in the winter for a month it will heat as well. In the real good weather I'll open the 7'x8' door and all the man doors. I only have a doorway between the two rooms. There's somethings with it's butt sticking out a hole in the wall, that looks nice next to the pool. With a heat pump (they work good in AZ) you can put on a digital thermostat that will control turn on, turn off different tempertures over a 24 hour period, then it repeats the next day. Remember I don't pay for electricity.

[Walker]

"Remember I don't pay for electricity"

How do you manage that???

[Vern2]

Walker,
I'm a retired telephone man. Telephone stuff is mostly DC. That's only a small jump to AC. The solar guys showed me a thing or two. Like solar panels are wired like batteries. Beside installing hundreds of remote centrals offices. One with 19,000 phones (Arizona State University). I installed the DC power systems as well (150 to 250 amps). 1200lbs racks of batteries. I was an installer only, for 33 years.