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Old 08-03-2017, 11:25 AM   #21
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Since were in the middle of a heat wave, this project has become a top priority. Yesterday, I cut out a piece of 3/4 plywood, using the old window as a pattern. First I layed out and cut the hole for the A/C, off to one side to clear the interior cabinet. Since the door has quite a curve from top to bottom, I also had to cut a series of relief cuts in the plywood to allow it to bend. Starting at the bottom, I drilled out the bolt holes and slowly bent the wood to fit. Once the wood was bolted in, I slid the unit in, turned it on and went inside to cool off. Today, I'll finish mounting it using a combination of 90deg brackets and wood trim, then take it all apart, seal and paint it, and move on to the next project. Total cost, including plywood was under $300.00.
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Old 08-03-2017, 01:14 PM   #22
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I really like that! Hope it cools off inside quickly cause I want to see:
- support rigging inside
- clearance with spare tire outside
Also, pretty paint when it's cooler....
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Old 08-03-2017, 01:16 PM   #23
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Also, was it easy to find an A/C unit with such a low profile for the interior?
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Old 08-03-2017, 01:45 PM   #24
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Maybe I missed it, but since you completely removed the glass and the surround, does the plywood stay in place while driving, and does the AC stay in place while driving?


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Old 08-03-2017, 03:39 PM   #25
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Originally Posted by BroncoHauler View Post
Maybe I missed it, but since you completely removed the glass and the surround, does the plywood stay in place while driving, and does the AC stay in place while driving?Herb
The plywood is bolted in place, (using more bolts than the widdow did). The A/C will stay in place (I hope), until winter time, when I will put the stock glass back in. The unit weighs about 40lbs, and hangs out about 12 inches, so there is a lot of leverage on the plywood. I'm making a couple heavy duty triangulated brackets that will hopefully handle the forces generated when the van pounds over washboard, goes through a pot hole or launches off an unseen jump. I'm more concerned about how the compressor, fan and other guts in the unit are mounted. Still, even if the compressor commits suicide or the fan comes apart, I'm only out $125 and I'll just get another one. When I bought it, I simply looked for the smallest one I could find (5000btu and 400w) It also turned out to be the least expensive one available.
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Old 08-03-2017, 05:33 PM   #26
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If you haven't seen it, Safari Condo has a nice-looking and (seemingly) well-designed rear window AC setup for their GM van models. Might give you a few ideas, too. I like the flip-up AC unit cover, for example. Can't quite tell how they support the AC unit underneath, though.

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Old 08-03-2017, 05:41 PM   #27
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... The A/C will stay in place (I hope), until winter time, when I will put the stock glass back in...
Just thought of something. Since an AC unit is designed to flow air through it, do you now have the possibility of having exhaust fumes enter your van through the AC unit while you drive?

Give it some thought so you stay safe.


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Old 08-03-2017, 05:49 PM   #28
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If you haven't seen it, Safari Condo has a nice-looking and (seemingly) well-designed rear window AC setup for their GM van models. Might give you a few ideas, too. I like the flip-up AC unit cover, for example. Can't quite tell how they support the AC unit underneath, though.

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They have some nice things on that site, and I really like their rooftop AC unit. Too bad both their rooftop and rear window unit can only be use on shore power.

I also really like their cargo box with integrated bike rack.


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Old 08-03-2017, 06:15 PM   #29
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I'm doin' the window unit thing but a 110 version of this is what I'm lusting for
https://www.truma.com/int/en/air-con...phir-vario.php
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Old 08-04-2017, 08:57 AM   #30
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I'm doin' the window unit thing but a 110 version of this is what I'm lusting for
https://www.truma.com/int/en/air-con...phir-vario.php
55 amps @ 12v!!!
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