When you swap an old air handler for new equipment, the base size, undercut, and transition angles often don’t match. If your platform overhangs the coil or blocks part of the underside access, you’re choking airflow just as badly as running a duct that’s too small — and the equipment is rated assuming full access to that coil.

Elliot covers how to handle tricky framing transitions, when a double platform or extra plywood support is needed to keep things from sagging over time, and why taking the harder cutting path on a tough transition is worth it if it means preserving full return airflow. He also touches on filter access sizing and quick tips for cutting risers cleanly.

If you’re a technician installing or replacing air handlers, these platform cutting techniques will help you avoid creating airflow restrictions that cause long-term system issues — and help offset the airflow deficit that’s often already built into the ductwork.