How to Cut Into Existing Ductwork in a Basement

You may need to cut into existing basement ductwork when making room additions or adding vents. Ductwork is typically constructed of aluminum, a material that is convenient to work with as long as you avoid bodily contact with sharp, cut edges. You'll need to use a few basic tools, such as an electric or cordless drill and tin snips, when cutting aluminum. Tin snips are easy to manipulate and use when cutting ductwork material.

Felt-tip marker
Measuring tape
Stepping stool or small ladder (optional)
Object being attached to ductwork
Electric drill
½-inch drill bit
Tin snips
Gloves
Safety glasses

Instructions

- 1
  Locate the ductwork in the basement and determine where you will make the cuts. Make layout marks on the ductwork using a felt tip marker by either transferring the measurements from the object that you're attaching to the ductwork, or by tracing around the object while it's pressed firmly against the ductwork.
- 2
  Put on a pair of safety glasses and heavy-duty work gloves. Make sure that your work area is accessible and clean of clutter. Use a stepping stool or small ladder for easier accessibility.
- 3
  Attach a 1/2-inch drill bit to the drill chuck. Drill a hole through the ductwork within the lines of the cut out, or waste material.
- 4
  Slip the tin snips' open nose through the drilled hole and start cutting along the layout lines. Remove the tin snips and drill additional holes into the ductwork as needed.
- 5
  Vacuum any dust or debris from around the ductwork hole to prevent it from clogging the ducts in other areas.

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