Custom Sheet Metal Fabrication in New Bern, NC

We fabricate parts that connect and correct ductwork, including transition pieces between a duct and an equipment opening, custom duct sections for runs that standard sizes cannot fit, branch fittings and reducers, and return air openings. We also make adapters for equipment connections when a new system differs from the one it replaces. Each part is built from the dimensions recorded on site, so the finished piece matches the opening it serves.

A standard fitting works when the duct size, height and angle match the opening without forcing. Signs that a custom piece may be needed include a gap that cannot be sealed, a joint that has to be bent to connect, a room that receives too little air or an opening that was altered during a remodel. We measure the connection and explain which option fits.

We measure the existing duct or opening at both ends of the connection, including height, width and any offset. We also record the angles, elevation changes and obstructions the piece must clear, along with the position of the equipment connection. Surrounding framing, joists and clearances are noted as well. These dimensions go into the written scope, so you can review the reasons behind the design before any metal is cut.

Sometimes. A leak at a connection that does not line up can often be corrected by fabricating a transition or section that meets both ends without strain. A leak caused by a worn or separated seam may only need sealing. We identify which problem you have after testing the connection, and we describe any sealing work separately from a fabricated piece so you can compare the options.

We approach each job based on its measured conditions, whether the ductwork was installed by our team or by another company. Before fabricating anything, we check the existing ductwork, equipment connections and framing, then explain what the piece will correct. If the surrounding system has problems outside the custom part, such as undersized runs or failing sections, we describe those separately so you can decide how to address them.

It can. When a new furnace uses a different connection size or position than the unit it replaces, a custom transition or adapter often bridges the difference. Our team identifies those components during the installation evaluation and explains how each one affects airflow. You will see the reasons for each custom piece in writing, and our furnace installation page covers the rest of the scope.

Our technicians serve Havelock, Morehead City, Trenton, Jacksonville and Kinston from our New Bern base, and each community is listed in the coverage section of this page. If your property sits outside those communities, contact our team and we will confirm whether a visit is possible. The measurement and fabrication process stays the same wherever the property is located.

We fabricate custom ductwork pieces for commercial installations, including connections that need a precise fit at a rooftop unit. Commercial projects often involve larger openings and existing duct layouts built for different equipment, so accurate measurements carry extra weight. For new rooftop equipment, our commercial HVAC page describes how existing ductwork is evaluated before any change is made.

Helpful preparation includes the make and approximate age of the equipment, the location of the duct or opening, and any photos that show the connection from several angles. Note which rooms seem to receive poor airflow and whether a recent remodel changed the framing. Clear access to the connection, along with any crawl space or attic area nearby, makes measurement more accurate.

Yes. Every fabricated part is sealed at its seams and checked for fit before installation, and each connection is tested once the piece is in place. We check airflow at the affected registers or equipment connection so the result is measured rather than assumed. The written record notes the dimensions, the sealing method and the location of the custom piece, which helps future technicians.