Run New Laundry Vents, step by step

Yes, this is a post about how to run dryer duct work and reroute HVAC vents. Why would I make a horribly punny reference to a 22-year-old Disney hockey movie if it were not? But first, some background. By the time Monday’s post was going up, David the framer was here putting the finishing touches on our new laundry room by adding that fourth and final wall (the one that will have the door that leads to the hallway).

He also brought in the wall that will eventually house the frosted door to the current storage / future TV room. I took the picture from this side to get around that lovely plastic sheet, which helps us keep some of the attic heat at bay.

Here is a full shot of the completed framing. I propped up the door simply to give everyone an idea of how much it will swing into the room (it is 8′ deep, so there is plenty of room for that door to swing without interfering with our washer/dryer/cabinetry).

But this post is not truly about framing, it is about some of those little annoying tasks that you sometimes forget about in all of the excitement of a big project. Annoying, but no less essential. So here are the three items we checked off our list before drywall could begin. They are not the most exciting, but I hate to skip over them for anyone else facing similar projects… so prepare yourself for plenty of photos coming your way.

Let us start with the new dryer vent. I read that for proper function (i.e. getting clothes dry and not starting lint fires) a dryer vent pipe should be no longer than 25 feet and for every 90-degree turn, you should subtract 5 feet from your length. Here is what our old set-up looked like, which I think was about 10 feet too long or had about 3 too many turns in it.

The good news is that by putting our dyer on the back wall of the new room, we were much closer to the exterior wall. But when we initially mapped out where the new vent could go (Plan A) it was not faring much better. To keep the pipes up and out of the way, it took nearly as many turns and nearly as much length. Boo. So we found a new path (Plan B) that was MUCH better and shorter by going under the attic steps… only it involved cutting a new hole in the exterior wall. That does not top my list of lively activities, but it had to be done. And I will explain later why we chose to still take it up the wall rather than exiting the house under the stairs.

To start, I needed to make a path under the step for the 4″ vent pipe to go. I used my Dremel Sawmax to cut the plywood top along the step joist so that I could easily reattach it later. Then I used a reciprocating saw to cut a 4″ wide section out of the 2×6″ for the vent to rest in.

I was planning on reusing the existing metal vent pipes since they were in good sufficient condition and I had a lot of pieces to choose from. All they needed was a good cleaning first, which I did by taking them all apart and using a long bristled brush to scrape them clean along with my Shop Vac.

Then I began piecing them back together. Pipes like these have a crimped end that makes them easier to fit together. I read once that you want your crimped ends facing the same direction of the airflow so that air does not escape around the crimping. Once fitted together, I sealed everything with metal-faced duct tape (note: not duck tape!).

Once I had all of my pipes fitted together, I began to position them to run them under the stairs and up the back/exterior wall. You can see that I made an opening in the side of the step for the duct to pass through there, and I held everything in place with some steel hanger straps.

That bottom pipe extended way too far into the room, so I cut it down using my metal snips. I left it a little long so that I can cut it to its final size once the room is more wrapped up. The green painters tape is simply so we do not cut ourselves on the raw edge while working.

Next up was putting the new hole in the exterior wall. Lively. I began off by drilling a pilot hole from the inside to mark roughly where the new vent hole needed to go. This was mainly to make sure I placed the hole directly above the pipe that I simply installed.

Then I headed outside to start making the big hole in the siding. More lively. Especially the ladder part. Yay. Anyways… I did this using a 4 1/8″ hole saw (which you will see closer in a moment). I hoped to start from the outside to make sure I was placing it in the middle of a siding board (and not awkwardly spanning two of them). The pilot hole I made from the inside helped me make sure I was drilling in the right spot.

Outside I only made it through the hardboard siding (not the plywood beneath it). I did not want to spend any more time up on that ladder than I had to, so I came back inside to do the rest. The 4 1/8″ hole saw bit made a fresh pilot hole for me to follow so I could be sure everything lined up.

With the hole cut all the way through, I could install the new dryer vent on the outside. I picked up one that resembled the original one, since they’ll both be living up there until we go through the trouble of removing the old one and patching the siding (we have simply capped and sealed it from the inside for now). Oh and Sherry painted the new one to match the siding before I installed it so there’d be less work to do up on the ladder.

Before climbing up I put a ring of silicone caulk around the back of it, that way it’d have a pleasant weather tight seal from the get -go.

It took a bit of finagling to get it in (the 4 1/8″ hole took some sanding down to get the 4″ pipe through) but eventually it was in and I could screw it to the siding for a pleasant firm hold. And this photo shows why we chose to put the new vent as high as we did, rather than exiting the house under the attic stairs. That would’ve put the vent barely above that bit of roof below, meaning lint would’ve built up on the shingles. So because we had to take it higher no matter what, we figured we’d put it in line with the old vent, simply so things would line up (and not look all diagonally janky until we patch that one down the line).

Back inside I trimmed off a bit of the vent pipe that stuck into the room and connected a semi-rigid vent pipe to it, complete with more metal faced duct tape and another ring of silicone caulk.

Then I simply had to reattach the section of the stair that I had cut off and we were back in business. Well, I guess we need the dryer installed to truly be back in business – but you know what I mean.

We will take a brief interlude from duct talk to address the floor for a second, which you will notice is quite a bit lower in the new laundry room at the moment. We want the tile that is going in there to be as flush with the hardwoods as possible, so we needed to build up the subfloor a bit.

I did some math and figured I’d need a 3/4″ layer of subfloor, a 1/2″ concrete backer board (for tiling on), plus the height of the tile & thinset to get myself flush with the hardwood floor. Since I was not going to fit two 4 x 8′ pieces of subfloor in our car, I took this as my cue to rent the $19 Home Depot truck and get plenty of my big materials – including all the drywall and insulation.

The 4 x 8′ pieces of 1/2″ OSB subfloor took a bit of trimming with my circular saw before bringing them up to the room, but all things considered it was not too hard to get the two sheets to fit nicely, and then I glued and screwed them down (gluing can assist cut down on any creakiness down the line). Here is the first one going down.

Now let us get back to ducts. This time we are talking about the HVAC variety, since this new laundry room has zero heating or cooling coming its way… despite the main trunk line being so close (and the old laundry nook having its own dedicated vent).

I am certainly not a pro in this department and I had a bit of trouble finding assist online in this arena – but eventually this series had sufficient explanation and photos to give me the confidence to tackle it. Also, I noticed that Home Depot sold this “Add A Vent” kit – complete with materials, a tool list, and instructions. Perhaps this would be less scary than I expected?

Buuuuut… I did not in fact use the Add-A-Vent box. After purchasing it (it was $67) I realized I already owned some of the items that were included, and that I could buy the others for about $54 instead. One of those items being this “Speedi-Boot” that makes nailing in the new ceiling vent between two joists truly straightforward. So I simply returned the boxed set and used my a-la-cart purchases (but hoped to call out that kit here in case it helps someone else who might not have some of the supplies I already did).

The part where I got nervous was cutting into my main HVAC trunk duct. But with some guidance from this post, I traced out where I hoped my new collar to attach…

…and used a utility knife to cut out the insulation, exposing the metal vent beneath.

The walkthrough I was following did not truly assist me when it came to cutting the hole in the metal, but this video did. In short I hammered a flathead screwdriver in to puncture it, then used my metal cutters to go around the circle. There are likely better snips for cutting holes than mine, but they did the trick well sufficient.

The collar has a ring of tabs on it, half of which I bent outward (to rest on the outside of the vent) while bending the others inward (to go into the hole). Once I placed it in the hole, I reached through the top of the collar and bent the inward tabs the other way so they held snugly against the inside of the vent.

Then I pressed some foil duct tape firmly around the whole thing to create a tight seal.

Next up was attaching the insulated flexible duct that would connect the collar to the ceiling vent. It is fairly straightforward to cut to length using a utility knife, but you will need wire cutters to get through the inner wire coil. I held it in place with a zip tie, followed by more duct tape.

I used more zip ties to hang the flexible duct from the ceiling a bit so that it did not have any kinks or anything, since I did not want anything that might restrict airflow.

I am gonna leave that cardboard “dust shield” (their words, not mine) in the ceiling vent until we are ready to heat and cool this room, but I did swiftly kick on the A/C simply to make sure it worked. And in case you cannot tell by my thumbs up or cartoon air arrows, it did!

I realize that was not the most lively post in the world, but I am quite glad to have gotten that stuff out of the way so this room can start to come together in more significant ways… like drywalling, which we have already began! It is in fact starting to look like a room in here.

But I will share all the drywall-hanging details when it is done, which will hopefully be by Monday if all goes well. we have book photoshoots today and tomorrow so we are forced to switch our brains off Laundry Room Mode until Saturday, but at least we were able to get some laundry done at my parents house yesterday so we will not be stinky for the photographer.