I'm writing this to hopefully help other homeowners from poor HVAC contractors.

I hired a small HVAC Co. to install 2 systems. He finished the work but I have been consitently uncovering workmanship problems with the duct work. Here's my list.

System 1 The addition
1)Last December the contractor got the heat working so I could have the plaster guys come in. The HVAC contractor went on vaca and planned to finish when he got back (5 days later). I had to go into the attic for something and realized that the return was wide open...sucking cold air from the attic!

2)About several months after he was "finished" with one of the systems, I went into the attic and felt hot air hitting my face. Turns out one of the take offs from the plenum had a 4" gap in it...spewing hot air into the attic. He fixed it.

System 2, Existing structure
3)One of the take offs near the end of the plenum was not fully connected to the plenum. It was deflected off the plenum because of the rafters and the air ended up travelling between the insulation and the outer surface of the plenum. I fixed this since the contractor couldn't help me for at least several weeks.

4)The contractor finished the system in late July of 2007. On days where temps > 90deg, the system spewed a choking oil smell into the home. I had to shut the system down and leave the house. Contractor couldn't address the problem (too busy with other installs). He never came to trouble shoot it and ended up replacing the coil this year (thought it might be defective)! Turns out there was a 1" wide x 12" tall opening between the return plenum and the air handler! Hot attic air was getting sucked into the system, pollen and all! My son has severe allergies and paid for it.

5)The main plenum is about 4" taller than the air handler and as a result, the contractor used Aluminum tape to fill that gap. It's peeling back now so I had to repair it.

6)There was a 1" wide gap between the air handler and the main plenum similar to the one on the return side.

He came over today to fix the problems. He was very agitated and thought my complaints were ridiculous. We had a few choice words and I sent him on his way. I didn't want him to do a quick hack job so I'll have to do it myself. The sad part is that I think he believes he did a great job. I feel the need to warn others. Thoughts anyone?

Sorry for the length.