Sheet Metal Fabrication
Expert Sheet Metal Fabrication & Custom Ductwork in Saskatoon
Aviation Mechanical specializes in custom sheet metal work for residential and light commercial projects across Saskatoon. From precision-cut ductwork to chimney toppers and specialized metal fabrication, our team delivers exact-fit solutions that integrate seamlessly with your HVAC system. Whether you need custom fabrication for a renovation, replacement ductwork for an unusual space, or protective metal flashing for your chimney, we combine Armstrong ProTeam expertise with meticulous craftsmanship.
Get Your Custom Fabrication Quote Today
Why Choose Aviation Mechanical for Your Metal Fabrication Needs
Armstrong ProTeam Expertise
Our certified technicians combine training in HVAC installation and system design with hands-on metal fabrication skills. Every piece is engineered to match your specific equipment, ductwork configuration, and space constraints, ensuring airtight seals and proper airflow.
-
Precision Measurements & Exact Fit
We take on-site measurements and test-fit components before final fabrication. Custom ductwork that doesn’t fit wastes time and money; we fabricate to your space, not to a standard template, so every run connects perfectly and performs exactly as designed.
-
Chimney Toppers & Chase Flashing Done Right
Improperly installed flashing around chimneys causes leaks and draft problems. Our technicians fabricate and install toppers and chasers that deflect weather, maintain draft, and complement your roofline. We handle the critical seal between your chimney and roof structure.
-
Local Saskatoon Team Close to Home
For on-site fabrication and repairs, we’re close by. For custom sheet metal pieces, we fabricate in-house without the delays of mail-order parts. As a locally rooted contractor, we understand Saskatoon’s climate and building codes. Learn more about our company.
-
Integrated HVAC Knowledge
Most sheet metal shops work in isolation; we don’t. Our fabrication team works alongside our HVAC technicians, so every custom piece fits your heating, cooling, or ventilation system perfectly. No guesswork, no gaps, no retrofit costs.
-
Fair Pricing & No Hidden Costs
We provide detailed quotes upfront and explain exactly what’s included: materials, labor, precision cuts, and installation. Custom fabrication is not off-the-shelf pricing, but we keep costs transparent and competitive. Financing is available through Finance It.
Get Your Custom Fabrication Quote Today
Have an unusual ductwork layout, a chimney project, or a custom metal fabrication need? Contact our team for a site visit and detailed estimate. We’ll measure, design, and fabricate your solution. For more information on related HVAC services, explore air conditioning repair, heat pump installation, and furnace services.
Signs You Need Custom Fabrication Services
Poor Airflow in Renovated Spaces
If you’ve renovated your home and your HVAC system feels weak or uneven, the ductwork may not fit the new layout. Custom ductwork adapts your system to your space instead of forcing the system into an undersized or poorly routed run. Uneven temperatures, weak registers, and audible whistling are all signs that standard ductwork won’t work.
Chimney Chase Leaks or Draft Issues
Water stains near your fireplace, draft problems, or visible gaps around the chimney base point to failed flashing. A leaking chase or improper topper lets rain in and heat escape. We fabricate custom flashing and toppers that seal your chimney to the roof and maintain proper draft.
Unusual Equipment Installation Needs
Adding a mini-split, upgrading to a heat pump, or installing a heat recovery ventilator sometimes requires custom metal work. Standard connections may not match your existing space or equipment layout. We fabricate adapters, transition pieces, and protective enclosures on-site.
Retrofit Installation Around Obstacles
Renovations often create odd angles, tight spaces, and unforeseen obstacles. Rather than running ductwork inefficiently around them, we design and fabricate custom pieces that fit the actual space. Custom bends and junctions solve problems that off-the-shelf ductwork cannot.
Missing or Damaged Metal Components
If a damper housing is corroded, a junction is damaged, or you’re missing protective flashing, we fabricate replacement parts. New fabrication costs less than replacing entire sections of ductwork and can be completed in days, not weeks.
Industrial or Commercial HVAC Projects
New construction, commercial additions, or specialized spaces (shops, studios, warehouses) often need custom sheet metal. We work with contractors and facility managers to fabricate components that meet codes and match system specifications exactly.
Sweating Ducts and Condensation in Unconditioned Spaces
Bare single-wall duct running through an attic, crawlspace, or unheated garage often sweats when warm supply air meets cold metal, and that moisture drips onto framing, insulation, and finishes. If you see rust streaks on a duct exterior, damp insulation, or water staining below a run, the ductwork likely needs to be re-sealed and insulated rather than simply mopped up. Where condensation is the issue, we fabricate insulated or double-wall sections and seal every joint so the metal surface no longer drops below the dew point.
Recognize any of these? Tell us about your project and we’ll design a solution.
What Saskatoon Customers Say About Our Fabrication Work
When you need custom metal work done right, you are trusting a contractor with your home and your budget. Here is what homeowners and businesses across Saskatoon have said after we delivered.
Our Custom Fabrication Process at Aviation Mechanical
Site Assessment & Measurement
We visit your location to understand your ductwork layout, equipment, and space constraints. We take precise measurements, photograph the area, and identify any obstacles or unusual angles that affect the design. This step ensures every piece we fabricate fits perfectly the first time.
- Detailed on-site inspection of existing ductwork and space
- Precise measurements of all dimensions and angles
- Assessment of existing equipment and connection points
- Documentation of airflow requirements and access limitations
- Discussion of timeline, budget, and special requirements
Design & Fabrication Plan
Using your measurements and HVAC system specs, we design the custom piece and create a fabrication plan. For chimney work, we assess roof pitch and flashing integration. For ductwork, we calculate the optimal path that minimizes bends and maintains airflow. We confirm the design with you before fabrication begins.
- CAD layout or detailed sketch of the custom component
- Material selection (galvanized steel, aluminum, or stainless steel)
- Assessment of airflow, sizing, and efficiency impacts
- Review of building code requirements
- Confirmation of timeline and cost before work begins
Precision Fabrication
Our equipment and techniques allow us to cut, bend, and assemble custom sheet metal to exact specifications. For ductwork, we choose the seam and joint type to match the run, then seal every connection so it holds under working static pressure. For chimneys and flashing, we fabricate with proper overlaps and drains. Every piece is finished to prevent rust and ensure durability.
- CNC cutting for straight edges and complex curves
- Rolling and bending equipment for precise angles and diameters
- Pittsburgh lock and snap-lock seams on rectangular duct for a tight, rigid corner
- Drive cleats and S-cleats to join duct sections squarely and support the run
- Gauge selection matched to duct size and static pressure so panels resist flexing and “oil-canning”
- Mastic on interior joints and code-approved foil tape on exterior seams, rather than cloth duct tape that dries out and fails
- Surface preparation and finish (paint, galvanizing, or coating)
- Final inspection and quality check before delivery
Fit Test & On-Site Adjustment
Before final installation, we test-fit the piece on-site. If adjustments are needed, we make them immediately in our shop or at your location. This step catches fit issues before installation begins and ensures a seamless connection to existing components.
- On-site fit verification and alignment check
- Minor adjustments or refitting if needed
- Connection compatibility with existing ductwork or equipment
- Final approval before installation or handoff
- Photo documentation of fit and clearances
Installation & Integration
We install the custom piece, seal all joints, and integrate it with your HVAC system. For ductwork, we test airflow and verify balanced performance. For chimneys, we seal the flashing, test draft, and ensure weather protection. You receive a walkthrough explaining the new component and any maintenance needs.
- Professional installation of the custom component
- Sealing and insulation as needed for efficiency
- System testing and performance verification
- Documentation of installation and specifications
- Cleanup and removal of old materials
- Written summary of work completed and warranty coverage
Chimney Toppers & Flashing Fabrication
A leaking or improperly sealed chimney wastes heating fuel and lets rain into your home. We fabricate custom toppers and chase flashing for your exact roof pitch and chimney size, then install and seal them properly. No more draft, no more leaks, and improved energy efficiency.
Sheet Metal Fabrication Services We Offer
Custom Ductwork for Renovations & Additions
Renovating your home or adding a new room? Standard ductwork sizes and runs rarely fit. We fabricate custom ducts sized and routed for your exact space, ensuring proper airflow, efficiency, and no noise. Whether your project is tight basement runs, crawlspace routing, or attic installation, custom ductwork solves the fit problem.
Discuss Your Ductwork ProjectChimney Toppers & Flashing Fabrication
A leaking or improperly sealed chimney wastes heating fuel and lets rain into your home. We fabricate custom toppers and chase flashing for your exact roof pitch and chimney size, then install and seal them properly. No more draft, no more leaks, and improved energy efficiency.
Schedule a Chimney InspectionTransition Pieces & Adapters
Adding new HVAC equipment or reconfiguring your system? We fabricate custom adapters and transition pieces that connect your equipment to existing ductwork without costly rewiring or ductwork replacement. Perfect for heat pump retrofits, mini-split integration, and ERV installations.
Get a Custom Adapter QuoteDampers, Registers & Metal Components
Broken damper housings, missing registers, or corroded metal components? Rather than replacing entire sections, we fabricate replacement parts that integrate seamlessly. Faster, less disruptive, and more cost-effective than full ductwork overhauls.
Order Replacement PartsHeat Recovery Ventilator (HRV) Ducting
HRV installations require precise, sealed ducting to prevent energy loss. We custom-fabricate inlet, outlet, and drain pipes sized for your home and system. Every connection is sealed and insulated for maximum energy recovery.
Plan Your HRV InstallationCommercial & Industrial Metal Fabrication
New construction, facility upgrades, or specialized HVAC projects need custom sheet metal. We work with contractors and facility managers to fabricate components that meet code, match specifications, and integrate with complex systems. We handle shops, warehouses, light manufacturing, and commercial buildings.
Discuss Your ProjectDuctwork Sealing & Repair
Existing ductwork leaking air? We seal leaks with custom fitted patches and gaskets, or fabricate new sections to replace damaged runs. Sealed ductwork improves efficiency, reduces energy costs, and ensures even heating and cooling.
Schedule a Ductwork AuditFrequently Asked Questions About Sheet Metal Fabrication
Service Areas for Sheet Metal Fabrication
We provide custom fabrication and ductwork services throughout Saskatoon and nearby areas. Our technicians are based in Saskatoon and can reach nearby cities during business hours.
Don’t See Your Location?
We serve Saskatoon and communities within about a 30-minute drive. If your town isn’t listed, give us a call — chances are we can still help.
Related HVAC Services
Ready to Solve Your Sheet Metal Fabrication Challenge?
Custom sheet metal fabrication solves problems that standard products can’t. Whether you’re renovating a home, dealing with a chimney leak, or installing new HVAC equipment in an unusual space, our Saskatoon team has the skills and equipment to fabricate a solution that fits perfectly. We combine precision metalworking with HVAC expertise, so every piece we create integrates seamlessly with your system and your home.
We’re ready to visit your home, take measurements, and provide a detailed quote for your custom project. Our team works efficiently without cutting corners—you’ll get the right solution on time and within budget. We handle repairs, replacements, and complete fabrication projects with the same precision and attention to detail.
We also offer financing through Finance It to spread the cost of larger projects, and our “HIP” HVAC Inspection Program includes annual inspections to catch ventilation or flashing issues before they become costly repairs.