Malco FasGroov FGVK, FasGroov FGVKL User Manual

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Tools for Safe, Fast, Accurate Fabrication of

1 in. and 1-1/2 in. Fiberglass Ductboard

We’ll Show you

Step-by-Step!

FABRICATING SYSTEM

MALCO PRODUCTS INC. • 14080 HWY 55 NW • PO Box 400

Annandale, MN 55302 •

www.malcotools.com

• Engineered for Superior Performance / Limited Lifetime Warranty

• Conçu pour fournir des performances exceptionnelles / Garantie limitée à vie

• Diseñado para un desempeño superior / Garantía de vida útil limitada

SL17156A

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VEE-GROOVE KITS

SHIPLAP KITS

Introduction .......................................................4

SETTING UP TOOLS

Adjusting FasGroov Square ............................... 9

Hand Tool blade height adjustment ................. 10

Blade removal / replacement .......................... 14

Shiplap Fabrication ......................................... 16

Vee-Groove Fabrication ................................... 20

Related Tools and Accessories ........................ 24

The duct fabrication procedures outlined in this manual pertain to two common methods of one-piece duct construction in standard 1” OR 1-1/2” ductboard. For applications requiring ductwork larger than that which can be constructed from a single piece of ductboard, consult the NAIMA Fibrous Glass Duct Construction Standards Manual or your ductboard manufactures fabrication manual for information on the two-piece “U”, two piece “L”, and four-piece construction methods.

KIT CONTENTS

FGVK

Vee Kit for 1 in. (25.4 mm) Ductboar

Silver Tools

FGVKL

Vee Kit for 1-1/2 in. (38.1 mm) Ductboar

Gold Tools

FGSLK

Shiplap Kit for 1 in. (25.4 mm) Ductboard

Silver Tools

FGSLKL

Shiplap Kit for 1-1/2 in. (38.1 mm) Ductboar

Gold Tools

FABRICATING SYSTEM

1 inch Kit 1-1/2 inch Kit Cat. No. Cat No. Description

FGVK FGVKL Vee-Groove Kit with following:

FGV1 FGL1 #1 Tool FGV FGLV Vee Tool FGV5 FGL5 #5 Tool FGV6 — #6 Tool FGS FGS Square FGK FGK Duct Knife FGM FGML Male Shiplap Knife FGF FGFL Female Shiplap Knife FGC FGC Tool Case

1 inch Kit 1-1/2 inch Kit Cat. No. Cat No. Description

FGSLK FGSLKL Shiplap Kit with following:

FGV1 FGL1 #1 Tool FGV24 FGL24 #2/4 Tool FGV3 FGL3 #3 Tool FGV5 FGL5 #5 Tool FGV6 — #6 Tool FGS FGS Square FGK FGK Duct Knife FGM FGML Male Shiplap Knife FGF FGFL Female Shiplap Knife FGC FGC Tool Case

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INTRODUCTION

Shiplap Method

Vee-Groove Method

Tool Features:

• FasGroov Tool identification incorporates both the numbering system of fabrication machines and the traditional hand tool color coding system. FasGroov Tools are available for

both shiplap and vee-groove fabrication methods.

• Easy, turn-the-knob, blade height adjustment. Scrap lifts cleanly out of groove. Blades are also easily removed without removing screws.

• Molded plastic handles are ergonomically

designed to fit angle of grip and reduce arm and hand fatigue on-the-job.

• Extruded, anodized, aluminum body is durable and lightweight. Grooved surface on

sled bottom facilitates easy sliding.

#1 GRAY

#2/4 DARK ORANGE

ORANGE

BLUE

#1 GRAY

VEE RED

BLUE

Sled glides easily and cleanly removes scrap piece out of groove.

Molded handles ergonomically designed to reduce arm and hand fatigue.

Blades remove without removing screws.

Grooved sled bottom facilitates easy sliding.

Patent No’s.

5,040,297 5,077,899

Easy turn-the-knob

blade height adjustment

compensates for thickness

variations in standard

1 and 1-1/2 inch board.

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CUT FLAP

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Use #6 Tool

to shorten

length of

duct section,

by measuring

from outside

edge of material

to be scrapped.

Use knob under

handle to raise

or lower blade

and adjust

depth of cut.

• 1” FasGroov kits also include a #6 tool (Tan color coded FGV6) for creating duct sections less than standard 4 foot lengths. The #6 replaces a shiplap knife for making a shiplap groove at fitting end prior to closure of duct section. The #6 may also be used for two-piece and four-piece ductboard fabrication.

1/2”

FGV6

Easy one-piece layout:

• FasGroov Square permits fast and accurate layout without marking cuts or calculating add-on dimensions. Lay out ductboard as you

cut. Simply align dimension on FasGroov Square with right edge of previous cut and move across the board. Square is also easily adjustable for angled cuts.

Single blade knives:

• Single blade FasGroov Knives are safer to use and also feature comfortable molded handles. Male and Female Shiplap Knives can

be used on closed duct sections.

FGK

Duct Knife

use this point to cut fiberglass without tearing ductboard skin.

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For right or left hand use:

• Right hand orientation of 1” kits is easily changed by converting #5 Tool and FasGroov Square for left hand fabrication. Tool handles may also be turned around to provide left hand grip angle.

Right hand

operation.

Left hand operation.

CONVERTING FASGROOV SQUARE FOR LEFT HAND USE.

1. Remove the angle adjustment knob and the end pivot knob.

2. Position the ruler stamped leg so that the 3 holes are to your left. (Rule reads left to right.)

3. Remove the protractor for the “L” shaped leg by removing the two screws.

4. Flip the protractor over and install on the opposite end of the “L” shaped leg.

5. Place the “L” leg/protractor assembly on top of the ruled leg.

6. Align the pivot knob holes and install the pivot knob.

7. Install the angle adjustment knob in any of the fixed positions or the sliding position.

8. After converting your square for left hand use, double check the accuracy in the fixed 90° position with a roofing square. Built-in manufacturing hole tolerances will allow you to true the square.

Note: 1-1/2” Kits cannot be converted for left hand use.

SETTING UP TOOL

Adjusting Fasgroov Square:

PREDETERMINED SETTINGS

Place adjustment knob into hole corresponding to most used angles.

OTHER ANGLES

Place adjustment screw into protractor adjustment slot and tighten at desired angle.

STORAGE

Step 1: Remove angle adjustment knob and fold ends of FasGroov Square together.

Step 2: Place angle adjustment knob into the storage hole and tighten.

Ruler stamped leg.

Pivot knob.

Angle adjustment knob shown here in 90° predetermined hole setting.

Adjustment slot for other angles.

Storage Hole for angle adjustment knob.

Screws holding protractor to “L” shaped leg.

Protractor scale etched 2 sides for right or left hand use.

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Hand Tool blade height adjustment:

FASGROOV #1 TOOL

Push the FasGroov #1 Tool along the left edge of a test piece of ductboard. Measure the depth of cut of the female shiplap groove, it should be half the thickness of the ductboard (see illustration).

If adjustment is needed: (1) Turn the blade adjustment knob counterclockwise to lower the blade for a deeper cut or (2) Turn the blade adjustment knob clockwise to raise the blade for a shallower cut. Repeat adjustment until the proper depth of cut is achieved.

FASGROOV #2/4 and #3 TOOLS

Push the FasGroov #2/4 Tool and FasGroov #3 Tool through a test piece of ductboard. Measure the amount of fiberglass remaining between the foil backing and the deepest part of the shiplap cut (see illustration).

Repeat adjustment until the proper depth of cut is achieved.

#1 TOOL

FGV1

FGL1

Adjustment knob

Blade

1”

1-1/2”

1/2”

3/4”

1/16”

FGV24

1/16”

FGV3

1/8”

FGL24

1/8”

FGL3

1”

1-1/2”

1”

1-1/2”

#2/4 TOOL #3 TOOL

#1 #2/4 #3 #2/4

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FGV

1-3/4”

FGLV

2-5/8”

1”

1-1/2”

VEE TOOL

FASGROOV-VEE TOOL

Push the FasGroov-Vee Tool through a test piece of ductboard.

Measure the amount of fiberglass remaining between the foil backing and the deepest part of the vee-groove cut. There should be 1/8” of fiberglass remaining (see illustration for width of cut.)

Repeat adjustment until the proper depth of cut is achieved.

FASGROOV #5 TOOL

Push the FasGroov #5 Tool through a test piece of ductboard.

The blade should cut deep enough to skin all of the fiberglass off the foil backing. By using more pressure on the FasGroov #5 Tool, any remaining fiberglass may be cleaned off the foil.

Repeat adjustment until the proper depth of cut is achieved.

Note: It is important to use this tool according to the direction arrows on the label.

#5 TOOL

Use FGK Knife

to cut staple flap.

VEE VEE VEE #5

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Blade removal, replacement:

Since the blade adjustment mechanism is the same for all FasGroov Tools, this procedure applies to any tool requiring blade removal/replacement.

BLACK PLASTIC SUPPORT

BLADE ASSEMBLY

SCREWS

Loosen Screws Slide and remove worn blade assembly. Place new blade into the black plastic support and

retighten screws. Note: Initial cutting friction may be realized due to

rust prevention factory finish on the blade.

Blades remove

without removing

screws.

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SHIPLAP FABRICATION

#1 GRAY

#2/4 DARK ORANGE

FGK

Duct Knife

#3 ORANGE

#5 BLUE

Work left to right facing the factory-made female shiplap edge as your base edge for a standard 4-foot deep ductboard section.

Set the FasGroov Square on top of the ductboard. Place the ruled edge of the square flush against the base edge of the board.

Locate your desired inside duct width dimension (W1) on the ruled edge of square and move the square along the board base to align your width dimension with the right edge of the previous cut made with the #1 Tool. Place the left side of the FasGroov #2/4 Tool flush against the arm of the square and push the #2/4 tool along the arm’s length to produce a right hand shiplap groove.

Place the FasGroov #1 Tool flush against the left edge of the ductboard. Push the tool along length of left edge to produce a female shiplap groove.

#1 TOOL

#2/4 TOOL

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CUT

FLAP

Locate your desired inside duct height dimension (H1) on the ruled edge of the FasGroov Square and move square to the right along base of ductboard to align your height dimension with the right edge of the previous cut made with the #2/4 Tool. Place the left side of the FasGroov #3 Tool flush against the arm of the square and push the #3 tool along arm’s length to produce a left hand shiplap groove.

#3 TOOL

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Insert the FGK FasGroov Duct Knife into the right edge of the staple flap cut made with the #5 Tool. Cut completely through the foil to finish the grooving process.

Fold the duct Section together. Staple and tape the flap, join duct sections and install take-offs with manufacturer-approved products.

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SHIPLAP FABRICATION

#1 GRAY

#2/4 DARK ORANGE

#3 ORANGE

#5 BLUE

Move the square to the right again to align your width dimension (W2) with the right edge of the previous cut made with #3 Tool. Place the left side of the FasGroov #2/4 Tool flush against the arm of the square and push the #2/4 along arm’s length to produce a second right hand shiplap groove.

Move the square one last time to align your height dimension (H2) with the right edge of the previous cut made with #2/4 Tool. Place the left side of the FasGroov #5 Tool flush against the arm of the square and push the #5 along arm’s length to produce a staple flap groove.

#5 TOOL

FGK

Duct Knife

CUT

FLAP

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VEE-GROOVE FABRICATION

#1 GRAY

VEE RED

#5 BLUE

CUT FLAP

Work left to right facing the factory-made female shiplap edge as your base edge for a standard 4-foot deep ductboard section.

Set the FasGroov Square on top of the ductboard. Place the ruled edge of the square flush against the base edge of the board.

Locate your desired inside duct width dimension (W1) on the ruled edge of square and move the square along the board base to align your width dimension with the right edge of the previous cut made with the #1 Tool. Place the left side of the FasGroov-Vee Tool flush against the arm of the square and push the Vee Tool tool along the arm’s length to produce a vee groove.

Place the FasGroov #1 Tool flush against the left edge of the ductboard. Push the tool along length of left edge to produce a female shiplap groove.

#1 TOOL

VEE TOOL

20 21

Locate your desired inside duct height dimension (H1) on the ruled edge of the FasGroov Square and move square to the right along base of ductboard to align your height dimension with the right edge of the previous cut made with the Vee Tool. Again place the left side of the Vee Tool flush against the arm of the square and push the tool along arm’s length to produce a vee groove.

FGK Duct Knife

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VEE-GROOVE FABRICATION

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#1 GRAY

VEE RED

#5 BLUE

Move the square to the right to align your width dimension (W2) with the right edge of the previous cut. Place the left side of the Vee Tool flush against the arm of the square and push the tool along arm’s length to produce a third vee groove.

Move the square one last time to align your height dimension (H2) with the right edge of the last cut made with Vee Tool. Place the left side of the FasGroov #5 Tool flush against the arm of the square and push the #5 along arm’s length to produce a staple flap groove.

#5 TOOL

Insert the FGK FasGroov Duct Knife into the right edge of the staple flap cut made with the #5 Tool. Cut completely through the foil to finish the grooving process.

Fold the duct section together. Staple and tape the flap, join duct sections and install take-offs with manufacturer-approved products.

FGK

Duct Knife

CUT

FLAP

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For use with wire-reinforced fiberglass ductboard walls to restrict duct wall deflection on positive pressure supply ducts. The volcano profiled reinforced washer seats flush to the ductboard surface. A 1/8-inch (3.18 mm) diameter hole accepts 12-gauge wire.

Use for fastening sheet metal components to fiberglass ductboard. The volcano profiled reinforced washer seats flush to the ductboard. A 7/32-inch (5.56 mm) hole accepts a #8 screw.

Galvanized Volcano Reinforcement Washers

Hole Cutter for Fiberglass Ductboard

Cat. No.

FLW Dimensions in. (mm) 2 ½ x 2 ½ x .030 (64 x 64 x 0.76) Hole Dia. In. (mm) 1/8 (3.18)

Cat. No.

RW732

Dimensions in. (mm) 2 ½ x 2 ½ x .030 (64 x 64 x 0.76) Hole Dia. in. (mm) 7/32 (5.56)

Fasloop Washer

Reinforcing Washer

FLW

FG1

RW732

Cuts 4 to 20” (102 to 508 mm) diameter holes in both 1” (25.4 mm) and 1-1/2” (38.1 mm) fiberglass duct.

Operation is fast and easy.

Supplied with a standard utility knife blade that safely stores in handle. Hole Cutter can also use the KBHC replacement blade for cutting 1-1/2” ductboard.

Cat. No. Description Net Weight oz. (g)

FG1 Fiberglass Duct Hole Cutter 7-1/2 (213)

REPLACEMENT 1-1/2” BLADE KBHC 1-1/2” Blade for FG1 Hole Cutter

KBHC Blade

for 1-1⁄ 2” board.

12045

12761

12047

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Double edged blade cleanly pierces duct, cuts both directions.

Built-in wire cutter completes the job by severing wire rib coil.

Cat. No.

FDC1

Length of Cut in. (mm) 4 (102) Tool Length in. (mm) 11-7/8 (302) Net Weight oz. (g) 11 (312)

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DK6S

Fine Honed Stainless Steel Double Edged Knife Blade

Compound Leverage

Wire Cutter

Comfortable Contour Vinyl Gripped Handles

FDC1

Ergonomic

cushioned

handle offers

comfortable,

sure grip.

Serrated edge aids cutting “flex” fiberglass wool duct.

Cuts Ductboard and Flex Duct!

It also cuts the wire rib coil!

Puncture resistant nylon sheath included with DK6S cushion gripped knife.

For cutting flexible fiberglass wool duct and ductboard. Double edge blades are ideal for blind cuts in “flex” duct.

Duct Knife

Flex Duct Cutter

Cat. No.

DK6S

Blade Length in. (mm) 6 (152) Net Weight oz. (g) 7 (199)

U.S. Patent No. 5,225,237

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The shear’s pointed bottom blade easily pierces duct to start the cut. The handy wire cutter is located away from the scissor blade edges. And a thumboperated latch ensures that the blade edges stay closed when not in use. Double edged blade cleanly pierces through outer skin and fiberglass wool insulation and cuts in either direction around the duct circumference. Use the handy built-in wire cutter to cut the hardened wire rib coil.

Double edged blade cleanly pierces through outer skin and fiberglass wool insulation and cuts in either direction around the duct circumference. Use the handy built-in wire cutter to cut the hardened wire rib coil. Use the tie tensioning mechanism to install a nylon tie strap that secures flex to a take-off collar. Use the wire cutter to cut excess nylon tie tail.

A knife, wire cutter & tie tool!

Multi-Purpose Flex Duct Tool

Cat. No.

FDC2

Length of Cut in. (mm) 4-3/8 (111) Tool Length in. (mm) 12-1/4 (311)

Net Weight oz. (g) 13 (369)

Cat. No.

FDC3

Length of Cut in. (mm) 4 (102) Tool Length in. (mm) 11-7/8 (302)

Net Weight oz. (g) 14 (397)

Thumb

operated

latch

Thumb operated latch ensures that sharpened blade edges on the FDC2 stay closed when not in use.

Wire Cutter

FDC2

FDC3

Use wire cutter to cut duct’s rib coil and trim nylon tie tail.

Tie tensioning mechanism

Thumb

operated

latch

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Scissor action plus wire cutter!

Flex Duct Shear

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Gripped TY4G and Un-Gripped TY4 Manual Cut-Off Models feature comfortable handle openings and reduced pinch-point. These long-life tools also feature a unique, non-slip, notched gripper to ratchet and set thick and thin nylon ties.

TY6 Model with Automatic Cut-Off can be set to engage blade and cut off the nylon tie tail when desired tension is reached. Designed for continuous use on thick ties, the TY6 features contoured cushion gripped handles and a long-life notched gripper.

Non-slip, notched gripper!

Features Automatic Cut-Off!

Manual Cut-Off Tensioning Tools

Adjustable High Leverage Tensioning Tool

Cat. No.

TY4 / TY4G (Gripped)

Tool Length in. (mm) 6 (152) TY4 — Net Weight oz. (g) 10 (284) TY4G — Net Weight oz. (g) 11 (312)

Cat. No.

TY6

Tool Length in. (mm) 8-1/2 (216) Net Weight oz. (g) 15 (425)

U.S. Patent No. 5,048,575 U.S. Patent No. 5,048,575

Cutter Handles

T Y4

Cutter Handles

T Y4G

T Y6

Adjustment Knob

Excess Tie

Cutting Blade

Features hardened steel stampings with weather resistant nickel chrome ﬁnish.

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Quickly installs on 4-inch to 16-inch diameter flexible fiberglass wool duct to support a 90° elbow support. Reduces energy consumption by eliminating air flow restrictions and increasing air flow efficiency. Lightweight, 100% recycled polymer construction. Use with 36-inch and 48-inch nylon ties (Malco TY34 and TY48).

These Outdoor Rated UV Resistant Ties are made of 100% Nylon. A one-piece adjustable, self-locking design makes them easy to install for a multitude of outdoor applications.

These Indoor Rated Ties are made of 100% Nylon. A one-piece adjust- able, self-locking design makes them easy to install for a multitude of indoor applications. Uses include securing HVAC duct take-offs and securing/bundling heavy tubing, hoses and cables.

Cat. No.

FDS1

Nom. Dimensions in. (mm) 15 x 11-1/4 x 3 (38.1 x 28.6 x 7.6) Net Weight oz. (g) 3 (85)

Supports 90°

Flex Duct Elbow!

Flex Duct Support

32 33

TY11 TY24

Overall Length in. (mm) 11 (279) 24 (610) Width in. (mm) 3/16 (4.57) 3/8 (9.5) Thickness in. (mm) 3/64 (1.32) 3/32 (2.29) Min. Tensile Strength lbs. 50 175 Max. Adjustable Dia. in. (mm) 3-1/16 (78) 7-3/16 (179) Color Black Black For Malco Tie Tools TY4, TY4G TY4, TY4G, TY6

TY34 TY48

Overall Length in. (mm) 36 (914) 48 (1219) Width in. (mm) 3/8 (9.5) 3/8 (9.5) Thickness in. (mm) 3/32 (2.29) 3/32 (2.29) Min. Tensile Strength lbs. 175 175 Max. Adjustable Dia.In. (mm) 11 (279) 14-1/2 (368) Color Natural Gray For Malco Tie Tools TY4, TY4G, TY6 TY4, TY4G, TY6

T Y11

TY24

UV Resistant Adjustable Nylon Ties

Jumbo Heavy-Duty Adjustable Nylon Ties

TY34

TY48