My house was built around 1998 and has the original split system with a car
rier 3 ton condenser outside and the air handle with propane furnace in the
Because of its age, and the outside condenser making noises, I had someone
quote a new system. The quote started at 8,000 for an Amana basic system an
d went to 15,000 for a Bryant with all the bells and whistles. Ouch......
To make a long story short, the person quoting found some things that proba
bly need to be addressed. One, my filter grill is in a wall in the house bu
t there is no "box" behind the grill attached to the return air vent. There
is just a hole in the floor with the return air flex attached.
The installer made a note that under the house, the previous installer rath
er than attach a return plenum just ran the return line directly off the si
de of the air handler.
Lastly, there is a very small "plenum" just covering the A coil. from this
is about 3 feel of flex duct that attached to the hard metal main 18 inch d
uct the supplies the branches that go to individual rooms.
So, I would like to build a filter housing, return air plenum, and maybe bu
ild a supply plenum myself 1st. Then maybe decide if I want to tackle repla
cing the current condenser/air handler.
My question is, how would you go about this size wise and mainly, is it nec
essary to use galvanized sheet metal or better to use regular metal then pa
int it? I can mig weld seems if necessary, but obviously that destroys the
galvanized coating. What gauge would you use?
Thanks for your help!
7 years ago