How to Fix an Aluminum HVAC Tube

HVAC, or heating, venting, air conditioning, tubes carry air to or from the furnace or the blower for an air conditioner. The tubes, also known as ducts, may be made of a variety of substances, including aluminum. Unless it is a small hole, the best way to fix the HVAC tube is to replace it. Tubing is available in multiple widths and lengths at most home improvement and hardware stores. Fixing the tube can be done in two hours or less, depending on your skill level, with common household tools.

Screwdriver
Measuring tape
Aluminum tube ducts
Self tapping screws
Aluminum tape

Instructions

- 1
  Fix small holes with aluminum tape. Cut a length of tape that is long enough to cover the hole and the area surrounding the hole. Smooth the tape so there are no wrinkle; wrinkles allow air to escape from the system.
- 2
  Fix large areas by removing the section of tube that needs to be repaired. Usually there are screws at each end where that section of tube joins with another. Once you have removed the screws, keep them close by. You can reuse them later. If your joints are sealed with tape, cut the tape away with a utility knife to reveal the screws.
- 3
  Measure the piece that was removed for it's length and diameter so you know what size replacement to get.
- 4
  Insert the new tube section where the old one was taken from. Line up the punched holes in the new tube with the existing screw holes in the old tube. If they don't line up, you can make new ones.
- 5
  Attach the new tube to the old tube with screws. You can use the old screws if the holes line up. If not, use self-tapping screws to pierce through the tube to connect the pieces at each end.
- 6
  Wrap both joints with the aluminum tape. Make sure the tape is firmly attached all the way around the joint so no air gets in or out at the joints.

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