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Complex curved pipe through flange?

Complex curved pipe through flange?

Complex curved pipe through flange?

(OP)
Hi guys... I have a somewhat complex (to me anyways) deal, that I'm not totally sure how to tackle.

I've got what we'll call a lofted duct, which needs to meet a flange. The duct needs to immediately start to turn and form from round to oval, as soon as it starts. At the same time, it needs to do this while it is inside the flange.

That is, I can't have the profile go straight through the flange, then start with a loft, etc.

I originally drew the duct up as a surface, then thickened it, trimmed it, and mirrored it to create both halves of a duct. Then I extruded the flange onto the end. Only then did I notice that the duct does not hit the flange perpendicular on the other side, and my duct needs to be "inside" the flange so to speak. It's also almost "too big" for the flange, and on one side, will hang out of the side wall.

I tried to half ass it already, and extruded the flange inwards, then made some trim cuts on the inside to clean up where the flange poked through onto the short side radius- but it didn't work worth a damn basically.

Then I tried to extrude the flange as a surface, and was hoping to use a ruled surface or something back to the outer surface of my duct, but that wasn't going to work either.

I attached a photo- this is the original part I am replacing. It shows the short side radius where it  hits the flange while curving internally.

Any ideas would be appreciated guys.

TIA

Pete

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