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How to Add Another Air Return to Central A/C

Room additions and remodeling often change the heating and air conditioning demands on existing systems. While it may be obvious that supplying heated and cooled air will be addressed, many times an equally important factor of return air is overlooked. Returning conditioned air to the blower location is essential for a well balanced system. In the past this task was accomplished mainly by professionals; with the advent of great home improvement and tool rental companies, non-professionals can master this task.

Things You'll Need

  • Return air box
  • Marking pen
  • Leather gloves
  • Metal hole boring bit
  • Drill
  • 1-inch metal bit
  • Curved Air Force cutters
  • Takeoff fitting
  • Insulated metal or flexible duct
  • Cloth or metal strapping
  • Duct tape or metal duct tape
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Instructions

    • 1

      Locate the return air duct in or near the new additional space and decide whether the grill will be installed in the wall, floor or ceiling. Also, confirm that the size of the return will serve the area sufficiently.

    • 2

      Install the return air box between studs for walls; floor joists for floors or ceiling joists for overhead returns. Most boxes will have an opening into the room and a round or rectangular duct collar for the duct work.

    • 3

      Mark the location for the takeoff fitting on the existing return air box using a marking pen. Cut in the takeoff fitting using a metal hole boring drill bit sized for the fitting. In the alternative, drill a small 1-inch hole into the box and finish with curved Air Force cutters to follow the round cut.

    • 4

      Insert the takeoff fitting into the hole and bend over the tabs to secure the fitting.

    • 5

      Run the new duct work from the takeoff fitting to the new return box installed in Step 1. Use an insulated duct that is either metal or flexible and sized to match the takeoff fitting and the return box.

    • 6

      Support the duct work with cloth strapping or metal strapping to prevent crimping. Seal both ends completely using duct tape or metal duct tape.

    • 7

      Screw in the finished wall grille at the return location and complete by placing the appropriately sized filter inside the grille on the slots provided.

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Home Additions
  1. How to Add an Air Vent to a Room
  2. How to Add an Air Conditioner Return Vent
  3. How to Adjust an A/C Damper
  4. How to Make an A/C Vent Filter
  5. How to Add Ductwork in a Basement
  6. How to Know if Your A/C Duct Needs Cleaning
  7. How to Tell if an A/C Compressor Is Out
  8. How to Attach a Flex Duct to an Air Grill Return
  9. How to Replace an A/C Coil at Home
  10. How to Make a Return Air Duct Work
  11. How to Insulate a Window A/C
  12. How to Seal an A/C Air Return

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