Project Summary
Project Type
Hard Metal Duct Install
Location
Los Gatos, California
Duration
3 day install completed by 2 HVAC installers
Services Provided
- Complete Duct System Replacement with Rodent-Proof Hard Metal Ducts
The Challenge
A Los Gatos homeowner faced a severely compromised HVAC system with 11 crushed and damaged wire flex ducts in the crawl space, resulting in poor airflow, energy waste, and potential rodent infiltration. Additionally, two upstairs bedrooms lacked adequate heating and cooling due to insufficient ductwork. The home needed a complete duct system overhaul to restore proper HVAC performance while preventing future rodent damage.
The Solution
We removed all damaged wire flex ductwork and replaced it with durable, rodent-proof hard metal ducts throughout the crawl space. The project expanded beyond replacement to include adding two new supply runs serving previously underserved upstairs bedrooms, creating a custom plenum distribution system to deliver conditioned air efficiently to the second floor.
Project Scope & Key Components
Scope of Work:
- Removed 11 crushed and damaged wire flex ducts
- Installed 13 runs of hard metal ductwork with insulation
- Added 2 new duct runs to upstairs bedrooms
- Custom sheet metal plenum box fabrication
- Rodent-proofing throughout crawl space
Installation Process
Our comprehensive installation included:
Existing Duct Removal
- Removed all 11 existing damaged wire flex ducts from crawl space
- Assessed and cleared rodent access points throughout system
- Prepared crawl space for new duct installation
Hard Metal Duct Installation
- Installed 13 runs of rigid hard metal ductwork throughout crawl space
- Insulated all new ducts with bubble wrap insulation for energy efficiency
- Sealed all connections to prevent air leakage and rodent entry
- Mitigated all potential rodent access points using properly fitted metal plates
- Closed off gaps and sealed crawl space penetrations
Upstairs Bedroom Addition
- Ran new 10″ Alumaflex duct from existing plenum with 90° transition
- Reduced to 8″ hard metal duct running up through first-floor closet
- Extended duct to stair landing beneath existing windows
- Fabricated custom sheet metal plenum distribution box appropriately sized for dual-room service
- Connected 8″ supply duct from crawl space to new plenum box
- Installed two 6″ wire flex duct runs from plenum box to each upstairs bedroom in opposing directions
Return Air System
- Removed existing 18″ wire flex return from above floor level
- Installed hard metal return duct connecting to plenum box in closet
- Connected to existing return filter grill for proper air circulation
The Results
The homeowners now enjoy dramatically improved HVAC performance with proper airflow throughout the entire home, including the previously underserved upstairs bedrooms. The rodent-proof hard metal duct system eliminates the risk of pest damage and contamination while the insulated ducts prevent energy loss and reduce utility costs. Air quality has improved significantly with sealed, clean metal ducts replacing the old compromised wire flex system. The custom plenum distribution ensures balanced airflow to both upstairs bedrooms, creating consistent comfort on the second floor. This comprehensive duct replacement and expansion has transformed the home’s HVAC system from inefficient and damaged to a reliable, energy-efficient solution built to last for decades.
Photo Highlights
Our team completed this three-day hard metal duct replacement by first removing all 11 crushed and damaged wire flex ducts from the crawl space and assessing rodent entry points throughout the compromised system. We installed 13 runs of durable hard metal ductwork, insulating each with bubble wrap for energy efficiency and sealing all connections to prevent air leakage while strategically placing metal plates to close off gaps and eliminate rodent access points. The most complex aspect involved creating a new supply system for two upstairs bedrooms by running 10″ Alumaflex from the existing plenum, reducing to 8″ hard metal duct through a first-floor closet, and fabricating a custom sheet metal plenum distribution box at the stair landing to split airflow in opposing directions. From this custom plenum, we installed two 6″ wire flex duct runs to deliver conditioned air to each previously underserved bedroom, ensuring balanced heating and cooling on the second floor. We also replaced the existing 18″ wire flex return with hard metal ducting connected to the closet plenum box and existing filter grill, completing a comprehensive system overhaul that prioritizes durability, efficiency, and rodent protection throughout.
System Benefits & performance Impact
This comprehensive hard metal duct replacement eliminates the chronic problems of crushed, damaged wire flex ductwork while providing permanent rodent-proof protection that prevents pest infiltration, contamination, and the costly damage that comes with it. Homeowners immediately notice improved airflow efficiency and more consistent temperatures throughout the home, with the two previously underserved upstairs bedrooms now receiving proper heating and cooling for year-round comfort. The sealed, insulated hard metal system dramatically reduces energy waste from air leakage and heat transfer, lowering monthly utility bills while the cleanable metal surfaces improve indoor air quality compared to deteriorating flex ducts that can harbor dust, allergens, and contaminants. Unlike wire flex that sags, crushes, and deteriorates over time, this durable metal ductwork is built to last decades without maintenance, providing reliable performance and peace of mind. The custom plenum distribution system ensures balanced airflow to the second floor while the rodent-proofing throughout the crawl space protects your investment and eliminates the health hazards and unpleasant odors associated with pest activity in HVAC systems.
