There have been several threads here about the lack of an outside exhaust vent for the range hood. Following the tips from one of the links, I did the following:
1) Knocked out the rectangle from the back of the hood. This was the hardest part, as the metal is very flimsy. I bent it up a bit.
2) Marked the corners of that rectangle. Then did a much better job measuring from holes and corners and re-did my marks on the wall.
3) Drilled the four corners. On the inside, I used a utility knife and cut through the luan and foam. On the outside, I taped and drew the rectangle, then used a rotozip (spiral) bit on my Dremel to cut the filon. My dremel bit was useless after this.
3.5) Mounted outside vent with butyl tape, screws, and silicone.
4) Re-mounted the hood, then fabricated a three-sided duct from a "roll and hook" flattened 5" duct tube. This metal was very workable. I tapered the hood end since that hole was slightly smaller than the vent frame. I left the bottom side of the duct for last, then foil taped it all together, then sealed the old exhaust side vents in the hood.
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-Scott, DW, DG, DB, and DD
2011 Passport 2590BH
2009 Ford F150 SuperCrew F
X4 5.4L w/Max Tow