Framing a furnace duct isn’t a difficult project. If you have the right tools and the instructions, this project can be quite easy and fulfilling. Once you have cut the hole in the wall and installed the upright frame pieces in Part 1, you will finish the framing by installing horizontal cross pieces and finishing it with wallboard and corner beads. Follow the simple instructions below to complete this project.
Step 1 - Take Accurate Measurements
A quality job begins with taking very accurate measurements. When performing work of this type, you should always measure twice and cut once. If you measure at least twice, you will be less likely to cut your pieces too long or too short. Once you’re certain about your measurements, cut the 2 cross pieces.
Step 2 - Install Cross Pieces
Once you have cut your cross pieces, install them. 1 goes over the top and 1 goes across the bottom. Hold 1 piece in place and secure it with a hammer and nail. Finish securing it in place with 1 nail every 6-inches.
You can also use a drill or electric screwdriver and self-drilling wood screws. Make sure that whatever you use is long enough to extend at least 2-inches beyond the frame piece to ensure that it’s properly secured.
Step 3 - Install Wallboard/Sheetrock
Once the frame is complete, cover it with sheetrock. Measure each piece twice before cutting to ensure accuracy. Secure the sheetrock to the studs and the framed in duct with either nails or sheetrock screws. You will need 1 screw every 12-inches.
Step 4 - Cut Corner Bead
Corner bead gives a finished and rounded look to sheetrock around corners. Place the length of corner bead up to one edge of the duct frame and place a mark on it at the point where it meets the next corner. Do so on all 4 sides of the duct frame.
Step 5 - Install Corner Bead
Corner bead requires drywall patching compound to secure to the wall. Put a quart of patching compound in the trough. Place the corner bead in its corresponding place and apply the drywall patch with the spreader, covering the corner bead completely. Do so on all 4 corners.
Step 6 - Finish Patching
Now it’s time to give your project a professional, finished look. Cut strips of drywall tape long enough to cover the joints between pieces of drywall. Depending on what kind of drywall tape you purchase, you may need some patching compound to hold it to the wall while you finish the patch. Apply lengths of drywall tape on the joints between your pieces of wallboard, pressing firmly to work the compound completely into the joint.
Step 7 - Sand and Finish
After allowing approximately 2 hours for drying, sand the patching compound to maintain a smooth finish. Using 100-grit sandpaper, sand all of the rough spots in the patching compound. Once you have a smooth patching surface, you can proceed to painting.