I fixed a kitchen fan exhausting to the outside (yes, always smooth metal - never corrugated). I found that there were very small areas in the fan housing ((that faces the top of the stove) that were not sealing at all ..... since they just wanted it fixed without having to by a new fan I simply used some sticky (back pressure it is called) one side aluminum tape and put small bits around the small holes that were allowing air to be pushed back towards the stove. The sticky aluminum tape did a great job - I didn't stop until there until all the leaks were plugged. It was leaking just about everywhere. I was tempted to get a caulking gun out! She was happy, I was happy...... on another note...many homes do not have air coming into the house! With new high efficiency furnaces (gas) the installers have used the hole at the top of basement foundations to install the 2 furnace vent and intake pipes. Now that they have sealed off that former fresh air vent...many homes no longer have fresh air coming into their home..... no air coming in....no air going out. It was a townhouse and the refused my request to have fresh air enter the home.......?really?.... so I put a covered and filtered vent over a small basement window (all metal with a heavy metal screen to stop creatures as well. I found just having a 2 inch or so opening allowed plenty of air into the house. It was a simple fix.....bit cool in the winter... but with a filter it was actually one step up from the old 4 inch circular hole in the upper foundation.

After much research, I just ordered the Best by Broan liner for inside of my custom hood. Will order a Broan blower (either inline or exterior. Appliance salesman and contractor will work together to let me try inline first, and if it doesn't perform well enough, get the exterior.) Link to the liner is below. Best by Broan is Boran's upgraded line. This was a really important decision, so I would've paid anything. I looked at every high-end brand, and found that the Best by Broan was the only one that met my specific needs. I chose it because: 1) The option to attach to an inline (this goes in the attic) blower, or an exterior wall or roof mounted blower. These 2 blower options allow for quieter operation, and, especially in the case of the exterior blower, more CFMs for greater smoke capture and removal. 2) The size. 58"+ is 18" wider than our 36" Wolf with griddle. It might be overkill, but ours will be mounted higher than the ideal 30-36", and I wanted the extra width for capture. 3) The baffles. Easier to clean than mesh, like the look, and GWers explained that baffles are probably quieter than mesh. They also explained that the wider the baffled liner, the quieter, b/c the air can rush into more baffles at one time. This was another reason I chose the 58" width. 4) 4 fan speeds, 4-level lighting, lights and controls are well laid out, like the four 50w halogens. 5) The wall switch option. It's important to note, if you want a wall switch to operate your blower, that some brands either don't offer one, or the wall switch actually disables some functions (like multi-level lighting) once it's installed. This was the case with a basic Broan, which is why we chose instead the Best by Broan. 6) During decision time, the Broan/Best by Broan tech department was really helpful, knowledgable, and available. Good luck, and try posting in appliances, too. Those guys are incredibly knowledgable and helpful. Here is a link that might be useful: Best by Broan Liner

The liner depth is 22.5"; but we are extending it out to be 24" from the wall to cover as much of the cooking surface as possible. The range is 25 1/8" deep to the front edge (not including the knobs and door handle). We can't go with a wider hood because of the existing upper cabinet layout - just not enough room. We have lived without a vent hood of any kind (long story - had a range with downdraft that died) for 7 years. We actually have a wooden upper cabinet over our current stove (ceramic electric range) at 28". Obviously don't want to go that low with the new hood but 36" just seems a bit too high. I think we have settled on 34-35" above the cooking surface.

I do not understand why people are fixated on hitting their heads on the hood. Seems to me the only way this is done is to put your face above a hot burner or pan. I can see it happening one maybe twice but you learn not to lean in so far. Kind of like when you were a kid and touched a hot oven and got burned, did it once and learned not to do it again. The hood looks fine, getting a shallower hood or moving it up might solve one problem but it will create more like grease not getting captured in the hood and vented outside. The steam and grease that does not go in the hood will end up on your cabinets, ceiling and all over your house. You have a beautiful kitchen, don't let it get ruined.