Apprentice answerHow do you line up twisted companion flanges without damaging the duct
2nd YearDuct Assembly, Seams & JointsStandard Correction
A twisted flange usually means the line is hung out of square. Loosen nearby hangers, square the faces with controlled alignment, bolt it cleanly, then re-level the run.
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Plain-English answer
When TDC/Ductmate corners will not line up, the problem is often the duct line, hangers, or previous joint being out of square—not the bolt hole itself.
Back off nearby hanger nuts enough to give the run controlled movement, square the flange faces, start the corner bolts without tearing holes, then re-level the hangers. If the flange is bent or the run is forced into a twist, stop before creating a permanent leak path.