rubber tie down straps
aka rubber tarp straps or bungee cords
available in most general and auto stores
works like a charm. all the banging caused by the furnace fan (pressure changes when the fan turns on and off) in the return air duct and plenum is gone.
What caused the problem in the first place?
short answer: metal fatigue. Fatigue (material) - Wikipedia
a thin metal surface that undergoes repeated stress reversals (fan off = no pressure; fan on = pressure) is subject to metal fatigue (bend a wire coat hanger back and forth repeatedly and eventually it will break).
Dents in the metal surface (during or after manufacture and construction, e.g. a thrown ball or toy, rough-housing kids, etc.) create stress points that add to the metal fatigue. As pressure cycles increase (fan off/fan on), the metal gets weaker, and "popping" noises from the furnace metal worsens.
The furnace noise problem could have been prevented by:
What caused the problem in the first place?
short answer: metal fatigue. Fatigue (material) - Wikipedia
a thin metal surface that undergoes repeated stress reversals (fan off = no pressure; fan on = pressure) is subject to metal fatigue (bend a wire coat hanger back and forth repeatedly and eventually it will break).
Dents in the metal surface (during or after manufacture and construction, e.g. a thrown ball or toy, rough-housing kids, etc.) create stress points that add to the metal fatigue. As pressure cycles increase (fan off/fan on), the metal gets weaker, and "popping" noises from the furnace metal worsens.
The furnace noise problem could have been prevented by:
- providing thicker metal surfaces (during manufacture)
- providing bracing (during manufacture)
- providing a walled enclosure for the furnace (immediately following installation)
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