How to Install an Envisivent Permanent Air Return Vent into a New Wall

How to Install an Envisivent Permanent Air Return Vent into a New Wall

In our last blog, we walked through how to install an Envisivent Removable Air Return Vent into an existing vent opening. In this blog, learn how to install an Envisivent Removable Air Return Vent into a NEW vent opening! If you missed our last blog, you can check it out here. 

The instructions provided are meant for the capable DIY, handyman or contractor working with a new build or renovations. If you are not comfortable with cutting drywall, and locating studs, as well as taping, mudding and sanding, we would recommend you speak with a contractor for further assistance. These instructions apply to the Envisivent Permanent Air Return Vents into a new location within your home. 

Let’s get installing! 

  1. It’s important to ensure that you choose the right product for your project by looking at the drywall size and the boot duct size as well as the function of the vent. Contractors and HVAC specialists will look at the PRODUCT SPECIFICATIONS that are shown on each product page to ensure they are installing the correct size. The vent sizes shown within the title of these products are the “BOOT DUCT SIZE” sizes. This is important to remember when selecting the correct size for a project. I.e: ENVISIVENT Removable Air Return Vent, 14” x 8” - the 14” x 8” dimensions refers to the boot duct size.

    PRO TIP: The “Boot” is a fitting that allows the duct piping to connect to the round pipe and is framed into the wall, floor or ceiling. The rectangular part is faced towards the direction of the room. The size of ductwork affects the amount of airflow and its velocity and is very important in how well the HVAC system operates. 

  2. Locate the area to which you would like to install a new air vent. Be sure the location works with your current HVAC system to ensure proper use of the vent. Do not cut drywall unless you are sure you are attaching the vent to your HVAC system. 
  3. Locate your studs and mark where your studs are located as a reference point when setting up the Envisivent Permanent Air Return Vent. 
  4. Remove the Envisivent product from its packaging. Place the vent on the wall with the sides of the vent overtop of the stud marks. This will ensure the vent will be mounted correctly to the studs.
  5. Ensure your Envisivent Permanent Air Return Vent is level and then take a pencil, outlining the vent directly on the wall - this pencil line will act as a guide to know where to cut the drywall.
  6. Position the air return with the angled slots either up or down depending on location of where the air return vent is being installed to avoid seeing into the opening.

    PRO TIP: When installing the Envisivent Permanent Air Return Vent, the primed side with beveled edges are to be facing you during installation.

  7. Next, cut the drywall along on the pencil line and remove the drywall piece. Clean up any ragged edges with a box cutting knife. 
  8. Place the permanent vent into the cut whole and fasten. Simply air nail onto the existing wood studs – if using drywall screws, pre-drill each place a screw is to be placed and countersink the screws properly.

    PRO TIP: We recommend you use an 1-1/4” length air nail or drywall screw and space every 6” to 8”. All air nails or drywall screws used for installation should be properly installed and countersunk to allow for proper drywall finishing.

  9. Once fastened in place, finish the beveled edge with Fiberglass Mesh Tape and Joint Compound (recommend Dura90 for the first coat) and blend into the existing drywall. Feather the Joint Compound away from the air return vent slots, not towards.
  10. Once the Joint Compound is dry as per manufacturer specifications, you can begin the process to blend the air return vent with the drywall.

    PRO TIP: a second skim coat of Joint Compound such as a ReadyMix Drywall Compound is recommended once the initial installation step has been completed.

  11. A touch up third coat with Ready-Mix Drywall Compound may be required to achieve your seamless finish.
  12. Once completely dry and smooth, paint over the vent in your desired colour.

    PRO TIP: If you are concerned with the Air Return Vent slots getting Joint Compound in them, you can install painter’s tape over the slotted area and remove once the mudding process is completed.


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