Yeah I figured I could just go with the rip it apart and duct tape it together method if I get desperate.
Taking a plenum apart won't be easy, you have the option of cutting it with a grinder and 1/16th metal blade. I've done that in the past, then used rolled aluminum as a joiner, some good caulking and a rivet gun to secure it.. then you're not relying on tape in a high pressure section of the system.
If you cut the top first and lift it you can get to the back, then reverse the order for reassembly by riveting the wall side first from the inside of the plenum, from there it's easy enough to stitch the top back together.
I am a semi-retired general contractor and not a HVAC specialist, but if I ran my plan by one he's likely shrug and say yes, it'll work in a pinch. Vulcem is great caulk, dunno if it's still around. Any good polyethylene caulk will work, I like Vulcem because it's thick and stays flexible.
Hope this helps