Yeah, the plastic brackets are a common weak point—seen plenty of those fail during inspections. Manufacturers often try to shave costs wherever they can, and sadly, brackets and mounts seem to be their favorite spot.
Switching to metal brackets is definitely the right move. Also, make sure you're securing the fan directly into the roof framing whenever possible. Attaching it just to plywood or OSB decking can lead to vibration issues and eventual loosening over time. If you don't have framing exactly where you need it, adding some blocking between rafters or trusses can really help stabilize things.
One more thing I'd recommend checking is sealing around the fan unit itself. Manufacturers usually provide a gasket or foam seal, but they're often pretty flimsy or degrade quickly under heat and UV exposure. Adding a bead of high-quality roofing sealant around the perimeter after installation can save you headaches down the road with leaks or drafts.
And yeah, sometimes you've gotta get a little creative—I've seen homeowners reinforce mounts with custom-cut aluminum angle stock from the hardware store. It's a simple fix that doesn't cost much and adds significant strength. Just be careful not to overtighten screws into metal brackets; snug them up firmly but avoid cranking them down so hard they warp or strip out threads.
Overall, taking the extra time to reinforce your install upfront is always worth it. It'll save you from climbing back into that hot attic later...
"Switching to metal brackets is definitely the right move."
Totally agree with this. When I helped my uncle install his attic fan, we ran into the same issue. Those plastic brackets just felt flimsy right out of the box, and sure enough, one snapped halfway through the install. Ended up making an emergency run to the hardware store for some metal replacements.
Also, good call on sealing around the fan. We skipped that step initially (rookie mistake, I know...), and after a heavy rainstorm, we had a small leak that soaked some insulation. Lesson learned the hard way. A bead of quality roofing sealant solved it permanently.
One other thing I'd suggest—watch your fingers with those aluminum angle pieces. They work great, but man, those freshly cut edges can be sharp. Ask me how I know...
Yeah, metal brackets are usually worth the extra hassle. I've seen plastic ones warp over time, especially in hot attics. One summer, I had a tenant call me up because their attic fan was rattling like crazy. Turns out the plastic mounts had softened and shifted just enough to cause vibration. Swapped them out for metal—problem solved. Also seconding the sharp edges warning... learned that lesson myself more than once.
"Turns out the plastic mounts had softened and shifted just enough to cause vibration."
Yeah, I've seen this happen more times than I care to count. Plastic components in attic spaces always make me skeptical—manufacturers claim they're durable, but real-world conditions often tell a different story. Heat buildup can be brutal up there, and plastic just doesn't hold up long-term. Metal brackets might be a bit more hassle initially, but they're usually worth it for peace of mind.
That said, I've also come across metal brackets installed improperly—too tight or misaligned—and they ended up causing vibrations too. It's not always about the material; installation quality matters just as much. Curious if anyone's tried using rubber isolation pads or washers between the bracket and fan housing? Seems like that could help dampen vibrations regardless of bracket material...
"Curious if anyone's tried using rubber isolation pads or washers between the bracket and fan housing?"
I wondered about that too. When I installed mine, the kit didn't come with anything like that, and honestly, I didn't even think about it until after the fact. Makes sense though—rubber washers or pads could probably cut down on some of the vibration noise.
As for plastic mounts... yeah, I'm pretty skeptical myself. My attic gets insanely hot during summer months, and I've already noticed some plastic parts warping slightly after just one season. But I also agree it's not just materials. When I first mounted my fan, I overtightened one side without realizing it. Took me forever to figure out why it was rattling so much. Loosening the screws slightly helped a ton.
Still, now you've got me thinking—maybe I'll go back up there and try adding rubber washers to see if that smooths things out even more. Can't hurt to try at this point...
