How To Cut Into Existing Ductwork

When cutting into ductwork, always use a sharp blade and make sure to cut squarely. It’s also important to wear safety goggles and a dust mask to avoid any injuries. If the cut is too big, use a piece of metal duct tape to cover it up until you can get it fixed properly.

How To Cut Into Existing Ductwork

There are a variety of ways to cut into existing ductwork, but the most common is to use a hand saw. This can be done by first measuring and marking the spot where you will be cutting, then using a straight edge to draw a line along the cut line. Next, use a hand saw to cut along the line. Be sure to wear safety goggles and gloves when doing this, as there may be debris or insulation that could fly up and cause injury. Another way to cut

-Tape measure -Pipe cutter -Hacksaw -Chisel -Hammer

  • Choosing the right tool for the job
  • Using a hacksaw, cut along the markings smooth the edges of the cut with a file or sandpaper
  • Measure and mark the ductwork

on – Cutting Ductwork – Ductwork Repair – Sealing Ducts When cutting into existing ductwork, it is important to be aware of the type of ductwork you are dealing with. There are three main types of ductwork- round, rectangular, and spiral. Rectangular and spiral ductwork can be cut with a hacksaw or a sawzall, while round ductwork must be cut with a tubing cutter. Always use caution when cutting

Frequently Asked Questions

How Do You Add To Existing Ductwork?

You may add ductwork to an existing system by either adding new ducts or branching off of existing ducts. If you are adding new ducts, you will need to measure the length and size of the ducts and then purchase the appropriate supplies and connectors. If you are branching off of existing ducts, you will need to measure the distance between the two points and purchase the appropriate connector.

How Do You Tap Into Existing Round Ductwork?

To tap into existing round ductwork, you will need to measure the diameter of the duct and purchase a connector that is the same size. Once you have the connector, use a hacksaw to cut the connector to size and then use a drill to create a hole in the center of the connector. Finally, use a screwdriver to attach the connector to the duct.

Can You Tap Into Existing Ductwork?

Yes, in many cases it is possible to tap into existing ductwork. However, it is important to consult with a contractor or engineer to ensure that the ductwork is the correct size and type for the intended use. In addition, the existing ductwork should be inspected for any damage or obstructions that could interfere with the new system.


When cutting into ductwork, always use a saw blade that is specifically designed to cut through metal. Be sure to cut the ductwork perpendicular to the length of the duct, and avoid cutting into any wiring or other components that may be housed inside. Once the cut is made, use a metal file to smooth out any rough edges.

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