If the grille is attached over the duct, just measure the grille and subtract the overlap, to determine the size of the duct. Generally a stamped metal grille has a 1-1/2″ to 2″ overlap, over the duct size. So if you measure your grille to be 7-1/2″ x 13-1/2″ than you have a 6 x 12 duct underneath that grille.

Duct Size

Measure the height and width of the duct. HVAC ducts are handmade and then banged out on site. Therefore, there is no such thing as a perfect duct.

Ducts may be handmade and never the same size, but grilles are standard sizes. So you must choose from a standardized grille selection to fit your non-standard duct. Grilles are standardized to the nearest even whole number in inches, like 4″, 6″, 8″, 10″, etc. So if your duct measures 7″ x 14″ you must determine if it will fit best with a grille made to fit a 6″ x 14″ or an 8″ x 14″. Determine which size works best by overall duct size and by proximity of any wall or baseboard molding which limits the size of the grille.

All grilles must be larger than the duct they cover. There must be at least a 3/4″ border around each edge of the grille so that you can attach it to the wall or ceiling. Different manufacturers make slightly different size grilles. A grille made to cover a 6×12 duct may be 7-1/2″ x 13-1/2″ on the small side and 8″ x 14″ on the large side.

Decorative grilles tend to be larger than the typical stamped metal grille as pictured above. Many of our grilles have a tapered edge, rather than the square edge of the stamped metal grille. The tapered edge improves the look of the grille. It has a look and taper typical of casing molding found around doors and windows. Use of the tapered edge, means a larger frame size around the grille, since the tapered edge is not suitable for the pre-drilled screw hole. Since the last 5/8″ inch of our decorative grilles is tapered, they can tend to be 1-1/2″ wider and taller than the typical stamped metal grille.

A 6″ x 12″ duct is covered by a stamped metal grille which is 8″ x 14″. A Louis XIV decorative grille to fit the same size 6″ x 12″ duct, measures 8″ x 14″. In other words, these decorative grilles have a larger frame with a tapered edge, which adds to the width and height of the outer dimensions of the grilles’ frame. The larger tapered edge is helpful in two respects, first it has a larger area where the screws mount the grille securely. Secondly, the larger tapered edge helps by covering any old paint lines resulting from removing the old grille.

Why are your grilles cast in urethane?

Our urethane resin cast grilles are equal in surface quality to investment casting (lost wax casting) quality at a fraction of the cost.  It is much superior to the rough and grainy looking surfaces of cast iron or cast aluminum grilles.

The urethane means a maintenance free product.  You should not have to re-finish, remove rust, corrosion or mold for the life of our exterior grade urethane resin grilles.  They can be used in damp or wet locations, like exteriors, bathrooms, kitchens and indoor swimming pools or the other rooms on the same HVAC system as the pool room.  The can be used to replace unattractive exhaust fan covers in bathrooms.

Our grilles will also reduct or eliminate the irritating high pitched noise problems often found with stamped steel louvered return grilles.  Urethane resin grilles will not vibrate and make noise like metal grilles do.  Use our grilles to replace noisy high pitched metal return grilles.