How to Replace Duct Board With Sheet Metal

Remove the section of duct board that you wish to replace with sheet metal. Duct board sections are connected with staples, which are then covered with duct tape. Cut through the duct tape with the craft knife. Pry up the staples with the screwdriver. If necessary, use the fiberglass knife to cut through the duct board to pull sections apart.

Assemble the sheet metal ducting you intend to install. Connect the first two pieces by sliding them together and then screwing in self-tapping sheet metal screws. Use a screw holder to help keep the screws in place while you work with them. Use at least three screws to join each section together.

Slide the sheet metal ductwork into the strapping material cradles that had been supporting the lengths of duct board. If it will not fit, unscrew the cradles from the joists to which they are attached. Screw the new strapping material to the joists, creating large enough cradles for the ducts. You can screw the sheet metal ducts directly to the strapping material for added stability.

Wrap the sheet metal ducts with insulation after the entire section is installed.