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Kinda Woodworking: Window Frame for A/C installation

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Project by Dave Rutan posted 06-08-2016 11:04 AM 607 views 1 time favorited 6 comments Add to Favorites Watch

I took on the task of installing a window unit air conditioner in a casement window at my church. The electrical outlet was previously run, so now the unit could go in. Because it was a casement window, I didn’t want to just put in a big old plywood panel and block off the view of the outside and any incoming light. The black panel is 3/4 inch plywood and is cut to fit into the space that would usually hold the screen. I brought the screen home to be sure my window would fit the space.

The window was made from a 1×4 that I had from somewhere. It must have been trash picked because it had been planed on the faces. I cut miters in it to form the window and simply ran a kerf along the inner edge of each board, keeping the alignment on each one. I bought a piece of plexiglas and cut it to size, just smaller than needed to fit between the kerfs.

Before assembling things I put a chamfer on the outside edge of the frame, so that it would transition visually with the existing woodwork at church. I did the same with the black painted plywood for the window unit, again to help the visual transition.

After gluing the frame together around the plexiglas, I carefully gave the faces of the frame a sanding to even out the joints and make it look purdy. I finished the wood with a few applications of Danish oil.

Because this is a casement window, for the sake of weatherproofing I’ll be uninstalling the A/C every fall and putting it back in every spring. The only problem I had is that my black plywood is about 1/8 inch too tall. It’ll fit better next year after I adjust the size. For this year a little pressure persuasion won the day.

-- Ni faru ion el ligno!





6 comments so far

View majuvla's profile

majuvla

9098 posts in 2328 days


#1 posted 06-08-2016 12:38 PM

OK, you are prepared for hot summer.

-- Ivan, Croatia, Wooddicted

View CFrye's profile

CFrye

8737 posts in 1300 days


#2 posted 06-08-2016 01:24 PM

Nicely done, Dave.

-- God bless, Candy

View Dave Rutan's profile

Dave Rutan

1430 posts in 1649 days


#3 posted 06-08-2016 01:46 PM

The week before I got this installed, it was hot. Now it’s not bad outside. I’m predicting a cool, rainy summer for New Jersey. In any case the vacation Bible school will get to use the A/C.

-- Ni faru ion el ligno!

View Oldtool's profile

Oldtool

2373 posts in 1651 days


#4 posted 06-08-2016 03:57 PM

Nice work, looks good.

-- "I am a firm believer in the people. If given the truth, they can be depended upon to meet any national crisis. The point is to bring them the real facts." - Abraham Lincoln

View DarrellJ's profile

DarrellJ

7 posts in 276 days


#5 posted 06-08-2016 09:54 PM

Nice job! I made a similar window, using a Home Depot 2X2. I made it a double pane to see if that helped with heat insulation. Mine also comes out in the fall. I think, however, yours looks better than mine. Did you spline the miters for strength? (I used biscuits in the miter faces)

View Dave Rutan's profile

Dave Rutan

1430 posts in 1649 days


#6 posted 06-08-2016 11:43 PM



Nice job! I made a similar window, using a Home Depot 2X2. I made it a double pane to see if that helped with heat insulation. Mine also comes out in the fall. I think, however, yours looks better than mine. Did you spline the miters for strength? (I used biscuits in the miter faces)

- DarrellJ

I didn’t spline the miters. In Glue I trust.

-- Ni faru ion el ligno!

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