Floor Register Won’t Fit – What To Do?

Due to the number of floor registers available in the market, purchasing the wrong size for the one you have at home is highly probable. And seeing that you are reading this article, you must be looking for the solutions to this problem. We have the answer researched and ready for you.

There are three ways to make a floor register that is too loose or too big fit into the duct opening.

  1. Stick adhesive-backed weatherstripping on the louver of the register to make it thicker.
  2. Install a trim along the inner duct opening on the floor to narrow the gap.
  3. Have a customized floor register that matches the size of the duct's opening.

We know you want more details about the given solutions, like how you will do them or what materials you must prepare. Are they all DIY tasks? We will answer each of these questions below. So keep reading to learn them all.

Things To Do When The Floor Register Won't Fit

Buying a new floor register that does not fit into the duct opening is terrible news. The good news is that the methods we are about to present are simple and easy since they only require measuring, cutting, and hammering skills.

Focus on floor vent in room with carpet

And to make things easier for you, we have prepared a step-by-step procedure for each method you can follow.

Method 1: Weatherstripping

In the first method, you will have to make the sidewall of the register thicker by weatherstripping. Below is the procedure on how to do this.

  1. Insert the register in the duct opening to see how wide the gap is. The size of the extra space will determine the thickness of the sponge rubber foam tape you will buy.
  2. Remove the register and place it on a flat, clean surface.
  3. Using a tape measure, get the length, width, and depth of the register's louver. Write the measurements down in a note so you will not forget the accurate numbers.
  4. Get the sponge rubber foam tape and lay it on the floor or a table. Roll out a portion that you think is as wide as the register's louver.
  5. Using a marker, mark some points on the weatherstrip tape according to the louver's length, width, and depth. To simplify the cutting, you can trace the dots to create lines. Use a ruler to make sure that they are straight.
  6. Follow the marks you made while cutting.
  7. Peel the adhesive cover off.
  8. Stick the rubber foam weatherstrip to one of the lengths and width louver.
  9. Put the register back into the duct to test if it is not shifting too much anymore. If there is still a gap, put the remaining strips on the other two sides for adjustment.

Method 2: Putting A Trim

Unlike the first method, where we thicken the register's louver, this time, we will make the duct's hole instead if it is too big for the cover. Here is how to do that.

  1. Prepare a tape measure, a pen, and a piece of material you can write on. Please place it in a dry place near you so you can get it anytime you need
  2. Insert the register into the duct and observe which side you need to adjust. Is it the length or the width?
  3. Once you figure out the part you will focus on, take the register out and set it aside.
  4. Measure the side of the duct opening that needs narrowing. For example, if the length of the duct opening is too long for the register, you will need to get the width and install the trim there to make it shorter.
  5. Go to your cutting area and get the trim that is thick enough for the gap you need to fill. Mark some points according to the side of the duct opening you got earlier.
  6. Cut the trim with a hand saw or a miter saw. Make sure you are not cutting it diagonally.
  7. After you cut all the pieces you need, attach them to the inner outline of the duct using a hammer and nails.
  8. Put the register back.

We have prepared a video to give you a visual representation of this procedure. Take a look at it below.

Do you have no idea where to nail in the baseboard trim? Check this article out to know where you should put them: Where To Nail Baseboard Trim?

Method 3: Customised Floor Register

Floor register on wooden floor

The first two methods require a lot of time and effort. If you do not have the luxury of both, this last method may be the one for you. You can have a custom-made floor register that perfectly matches your duct opening.

Having a professional make a personalized floor register is also ideal if you are not confident with your carpentry skills. If you are interested, search your local area to see if shops offer this service.

Are you planning to move your floor vent? Read this article to know how you will do that: How To Move A Floor Vent In A Mobile Home.

How Do I Know What Size Of Floor Register I Need?

How do i know what size of floor register i need, Floor Register Won't Fit - What To Do?

You will know the floor register size you need by measuring the outline of the duct opening where you will install it. For example, if the duct opening's width is 6 inches and the length is 10 inches (6x10), that is also the register size you will look for when you purchase one.

That is why making sure that you need to make sure that you are getting the correct measurement. Writing the digits down on a piece of paper on your phone can help you not forget them.

Is It Okay To Cover A Floor Vent?

White air conditioner duct grille cover against floor with brown carpet

Yes and no. It is okay to cover a floor vent only if you use a material intended for that purpose and the appliance is not running.

Another good reason to cover the floor vent is because of the toddlers or pets that may encounter it. The potential danger that may happen because:

  1. Their body parts, such as their hands or feet, can be tucked inside.
  2. The metal registers can be sharp enough to cut their delicate skin.

On the other hand, it is not okay to cover a floor vent if a flammable material such as carpets or curtains is blocking its airway. A blocked floor vent is a potential fire hazard, so check it once in a while to prevent fire from happening.

Learn more about covering your floor vent by reading this article: Can You Partially Cover A Floor Vent?

In Summary

To make the floor register fit in the duct's opening, you can stick adhesive-backed weatherstripping on the louver's sides to make it thicker. The second method is installing wood strips in the inner opening of the duct to decrease the hole's size.

Circular metal air vent in home surrounded by carpet floor

If you prefer a new one instead, there are available services that make customized floor registers according to the size you need. A custom-built floor register is convenient if you do not have the time to do the necessary process in the first two mentioned methods.