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Old 08-25-2009, 02:57 PM   #1
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Join Date: Sep 2003
Location: Destin, FL
Posts: 891
Basement AC Duct Leak

My AC was performing poorly (little cooling) & thought I lost freon. This forum discussed duct leaks, so I investigated & found a leak at the rear duct, between the rear cap and the rear wall. I took this photo lying on my back & the rear cap is to the right. The leak is at the bulge:

The duct breach is about half way up the rear cap, and about 3 to 4 feet past my extended arm reach. Removing the cap rang $$$ in my eyes, so came up with another repair method. Using metal duct tape (backing peeled off), I tacked the top to a 1"x3" four foot board as in below photo:

Then w/flashlite in hand, lying on my back, carefully put the board up and against the breached duct seam. Repeated the process 4 times to ensure coverage. BTW I first cleaned the area with a rag (attached to board) with some alcohol. No I did not have a shot myself.

The finished product is not aesthetically pleasing, but got the job done.

Anyway it worked. I submit this as an alternate to removing the rear cap, in those cases where the duct is reasonably reachable. Above that level, the cap may have to be removed. If the duct is physically separated, that's another story. An alternative might be a very thin grandchild with a penchant for RV repairs.

03 Adventurer 38G, W22, 22.5 Whls

Koni FSD's, TracBar rear, SteerSafe, 50A SurgeGuard, Eternabond; 2012 Honda CRV EXL w/Nav & AWD
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Old 08-25-2009, 03:06 PM   #2
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AFChap's Avatar
Winnebago Owners Club
Spartan Chassis
Join Date: Aug 2002
Location: ...hopefully on the road!
Posts: 5,227
Good job, Thudman!! I have heard of others who have used a "long stick" to help in the retaping, but your pictures are worth a lot of words. Only one question, you say you "tacked" the tape to the board at the top. Explain "tacked" ...and I presume that means the tape was hanging freely down the board and all you had to do was get it into position before allowing the board to come against the duct?
Paul (KE5LXU) ...was fulltimin', now parttimin'
2003 Winnebago Ultimate Advantage 40e
towing 2017 Jeep Grand Cherokee Limited
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Old 08-25-2009, 03:52 PM   #3
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Location: Destin, FL
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I put a very small piece of the duct tape (about 1/2" x 1/2") at the top of the tape & adhered it to the board edge so the tape (sticky side up) would be held in place on the board, but not unduly restrict sticking to the duct. Hope this 'splains it OK.

Also I recommend using the board on the DOWN stroke, to press the tape against the duct. When I pushed UPward on the tape (with the board) I caused mini ruptures in the tape (photo). The first tape applications were smooth, as I only pressed the board on DOWN strokes. And ensure your initial alignment is accurate, becuz the tape is really sticky.

03 Adventurer 38G, W22, 22.5 Whls

Koni FSD's, TracBar rear, SteerSafe, 50A SurgeGuard, Eternabond; 2012 Honda CRV EXL w/Nav & AWD
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