Bathroom fan install with new construction – lip around edge of fan doesn’t jive with ‘install drywall”

bathroomexhaust-fan

Feeling dumb here. Finishing up a remodel and have a Broan InVent fan with ~1/2" lip around the bottom. The instructions indicate attach the fan to the joists with the bottom 1/2 or 5/8" down and then "install the drywall".

Given that I didn't buy any of the magic stretchable drywall to go around the lip and snap back snug to the body, I have no idea of how that would be accomplished without cutting the hole at the outer perimeter of the lip which, in my thinking, is too big of a gap and makes no sense as the lip would provide no value. It also would not enable me to seal the outer gap so that is a no go in my specific air-tight/sound mitigating construction goals.

I can't bypass this issue of cutting the drywall tight to the body by just doing the install as a retro fit as the exhaust pipe is rigid so I couldn't pull it down.

The only thing I can think of at the moment is to bend the lips/flange up (or cut them off) as they seem to only be there for retrofits (two other fans I installed did not have any of these lips). Thoughts?

https://youtu.be/ZD3fsHHCsRU?t=58

Best Answer

In a retrofit, where the ceiling drywall is already installed, the flange at the bottom of the box goes against the existing drywall. The flange sets the installation depth, and the drywall cutout will be the size of the housing box.

In a new installation, standoff tabs in the housing set the installation depth from the joist bottom, and the ceiling drywall is cut to the outer perimeter of the flange. The drywall cutout will be the size of the flange edge, and the drywall does not tuck behind the flange.

When installing a new ceiling drywall panel at the fan, loosely screw it to the joists without burying the screw heads and cover the ceiling fan housing. You can't tighten the screws because the housing will keep the drywall near the box 1/2in off the joists. Poke a hole with a drywall saw somewhere within the box perimieter, cut to one of the sides, and carefully cut over the flange to the outer side. From there, cut around the outside of the flange, which is the cutout perimeter for the fan, using the flange's edge as your guide. It's not visible in the beginning but you can "feel" when the saw rides against it. You can do this with a drywall saw or a power tool like a spiral saw.

In both cases, new and retrofit, the grill will loosely seal off against the flange, regardless whether the drywall is behind the flange (retrofit) or butted to the drywall (new install).

None of this is mentioned in the manual or in the video, which I find baffling.