Custom Duct Transitions, Plenums & Fittings
When standard fittings do not fit the equipment or the framing, I fabricate the transitions, plenums, takeoffs, and boots that connect it all properly, often supporting an HVAC installer.
What I do
- Fabricate custom transitions between mismatched duct and equipment
- Build supply and return plenums to suit the furnace or air handler
- Make takeoffs, boots, and offsets for tight framing
- Adapt round to rectangular and change sizes cleanly
- Supply sheet metal support to HVAC installers on a job
Common problems I fix
- New equipment that does not match the existing plenum or duct size
- Off-the-shelf fittings that will not fit the available framing
- Sharp, restrictive transitions that kill airflow
- Leaky, taped-together connections at the air handler
Good-fit projects
- Heat pump or furnace swaps needing new transitions
- HVAC contractors needing a sheet metal sub for fittings
- Tight mechanical rooms with no room for standard parts
- Renovations where duct sizes change
A duct system is only as good as the fittings that connect it. When new equipment does not line up with the existing duct, or standard parts simply will not fit the framing, the connection ends up sharp, leaky, and restrictive. Those transition points are exactly where I fabricate custom metal so the system connects properly.
What I fabricate
Transitions between mismatched sizes and shapes, supply and return plenums sized to the furnace or air handler, takeoffs and boots, and the offsets that get a run past a beam or joist. Round to rectangular, a step up or down in size, a plenum that actually fits the equipment: these are the pieces that off-the-shelf catalogues never quite have for a real house.
Why forced-fit fittings cost you airflow
A transition that changes size too abruptly, or a plenum that is the wrong shape for the equipment, turns into a restriction and a leak point. Air piles up, the connection gets taped together, and the system loses performance right at the source. Fabricating the fitting to suit the actual geometry keeps the air moving and the joints tight.
Supporting HVAC installers
A lot of this work is for HVAC contractors who supply and set the equipment and need a sheet metal sub for the metal that connects it. I slot in alongside the installer, building the plenums, transitions, and fittings to their equipment and the home, so they can finish a clean install without competing over the heating-and-cooling side, which I leave to them.
Where I provide this service
I serve Squamish, Whistler, Pemberton, and nearby Sea to Sky communities. See service areas.
Related services
Frequently Asked Questions
Can you fabricate a transition when off-the-shelf parts do not fit?
Yes, that is a core part of what I do. I fabricate transitions, plenums, takeoffs, boots, and offsets to suit the actual equipment and framing, so the connection is clean and airtight instead of a forced fit full of tape and gaps.
Do you work directly for HVAC contractors?
Often. I supply the custom sheet metal side of a job, plenums, transitions, and fittings, so the HVAC installer can set their equipment and connect to clean, properly sized metal. I focus on the ductwork, not selling the equipment.