I will be replacing an electric forced air furnace (horizontal) in my crawler with a gas furnace. Currently the electric furnace is 20"W x 20"H x 39"L. The new furnace plus the filter rack will be about 35". This leaves me with approx 4" of room total to transition from the plenums to the furnace. The current return and supply plenums are 20" x 20" x maybe 48" sheet metal. Because the furnace return and supply openings are much smaller than 20" x 20" (14" wide Goodman GMES96), can I just position the new furnace right next to one of the plenums and block off the part of the plenum that is exposed/too big? I would like to make the transition a little smoother and reduce from the plenum size to the furnace over a greater distance, but I don't have the room and am hesitant to reduce the size of the return or supply plenums, as I am assuming their sizes were at one time engineered.
source https://hvac-talk.com/vbb/showthread.php?2222335-Furnace-to-plenum-transitions&goto=newpost
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