How to build a plenum for an cooling and heating air unit??
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Answers:
If you absolutely need to build one you need to have experience with sheet metal. Do not use duct board and metal tape. Duct board is an insulator, not ducting. With sheet metal sheers and a flange you can fabricate one. Cut the sheet metal 1 inch longer and wider than the opening, cut the corners to fit and bend the metal over the lip on the sides. Make the fit as tight as possible all the way around. Then cut the flange hole and use a flange that has bendable tabs. Bend the tabs on the inside of the metal plate, then seal with aluminum tape. Attach the completed plenum to the air handler with self taping screws, and then cover the entire seam with tape. Check out your local hardware store as they will have all of the materials that you need.
Sorry, you may have to go to a professional to have it made. Without the proper machinery and breaks, it is tough to bend one properly and fasten it together. If you know a local sheetmetal contractor, they can make one fairly quick for around $80.
you could build it out of ductboard and aluminum tape
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