How to Install a Return Air Vent - PlumbersStock.com

Links for Instructions and Supplies Below:
0:23 Overview -General information of How it pulls the air
0:31 Location of Return Air Induction -How it’s routed
0:44 Challenges -dynamics of how it pulls air from surroundings
1:18 How we’re going to solve the air supply issues and create more balance in the system
1:40 Choosing the best routing for the air
2:22 Thermo-pan to create duct for air-channel (Thermo-pan properties, “R” value/basic construction)
2:53 Reinforcing Thermo-pan to prevent vacuum pressure collapse of Thermo-pan duct
3:54 Installing Thermo-pan
5:20 Thermo-pan connectors to join Thermo-pan sheets
5:46 Using HardCast 550 Duct Sealant to seal Joints
6:06 Routing air channels between joists
6:37 Thermo-Pan Duct-work between joists
7:23 Venting TJI to using “Hole-Hawg” create air pathway between joists
8:06 Finishing instructions, what we did


Tools used for this job:
Porter Cable Nail Gun
https://www.plumbersstock.com/porter-...
Hole-Hawg High Powered Right Angle Drill
https://www.plumbersstock.com/milwauk...
Milwaukee 49-56-9645 Hole Dozer Hole Saw 4"
https://www.plumbersstock.com/milwauk...
Milwaukee 49-56-9305 Big Hawg With Carbide Teeth Arbor
https://www.plumbersstock.com/milwauk...
Smart Point BTFP12233 Corded Strip Brad Nailer
https://www.plumbersstock.com/bostitc...
Thermo-Pan
https://www.plumbersstock.com/categor...
Return-air Grille
https://www.plumbersstock.com/hvac/ve...
Baseboard Return-air grilles
https://www.plumbersstock.com/search?...

Phillip shows us how to install a return vent using Thermo-Pan. This type of installation is particularly useful when installing a return vent in an older home and allows you to utilize the existing construction.

Transcript:
Today we're going to install a return air supply for this furnace. Return air comes in the bottom where the blower cavity is. This is a gas furnace, it heats air with the heating exchanger and it goes through the air conditioner coil and out through the supply duct. In order to pull the return air from parts of the house we need, we're going install ducts. It doesn't have to be as extensive as the supply ductwork, because it is not hot air going through. If you pull air from right by the furnace it's going to be noisy and the system is not going to balance well -it will pull more air from the room that it's in, rather than from other areas of the house. Behind the furnace, there is a filter that goes into a utility room; we're going to duct a channel for the air to flow through it and into the bottom of the furnace. We have the channel framed out and we're going to add some support. Where it comes through are pipes/electrical; on a return it's no problem, but for supply that's not allowed. We've framed through the bay behind the furnace that going to go up into the floor base where TJI's run parallel. We need to go through the next TJI to duct into the hallway upstairs. To do that we're going to use Thermo-pan, which is light cardboard inside metalized sheeting that has an R-3 insulation value; together with adhesives and staples, we're going to create the bay.

I'll use 2"x8" reinforcements to prevent vacuum pressure from collapsing the bay. This bay lets the pipes and electrical go through, but still supports the Thermo-pan. I'm going to use a staple-gun because it's faster, but you can use panning nails, small nails with wide heads to anchor the Thermo-pan. Use caution with a staple gun because it can punch right through. Next piece is going to angle in and then go up into the base. I have two gaps I'll need to fill. I'm going to pan off the inside of it first and then I'll do a cover for the outside. To do the cover we need something to attach to and a support in the middle, so we're going to use some 2"x4"s. We have Thermo-pan connectors, are going to slip this one on. This will give us a good seal without having to use duct-sealant. With the angle-joint we will have to use sealant to connect this. Now I'm going to use Hardcast 550 duct sealant on the joints in order to seal and to keep it together. Now our return-air is sealed up to this point here. We have to block this off a little bit on the inside so air doesn't escape, but it's all in this bay. This bay has been blocked, so what we need to do now is block this other one so that the air can travel through these vent holes and into this bay.
The air will travel down the bay along the hallway, where it will hit one return, and then jump bays and go into the one upstairs.

http://www.plumbersstock.com