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Air conditioner install - what tool to cut the opening?


 

2004 ALiner Expedition. Never had A/C. Going to cut the opening over the passenger side wheel well. I’ve purchased the “kit” from ALiner Columbia. What is the best way to cut the wall?
Which tool (saw) is best?
Best to cut from outside?
Thanks!
? Ray Y.


 

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Hello Ray:

I've replaced our AC and added a skylight over the table area. I drilled the corners from the outside and then used a fine tooth saber saw blade. The cutting isn't hard, for us 0.5mm aluminum, Styrofoam and 4mm plywood, an easy cut. I did re-enforced the AC opening with aluminum.

Here are photos of the job, that included a new cabinet under the AC:

/g/A-frameCamperForum/album?id=124085

Good luck, Carl.

On 5/1/2025 2:17 PM, Ramon Yanez via groups.io wrote:

2004 ALiner Expedition. Never had A/C. Going to cut the opening over the passenger side wheel well. I’ve purchased the “kit” from ALiner Columbia. What is the best way to cut the wall?
Which tool (saw) is best?
Best to cut from outside?
Thanks!
? Ray Y.


 

If I were you I'd call aliner technical support and ask them how they recommend installing an air conditioner.? If you install it above the wheel well, you risk removing so much wall material it could make the wall too weak.? If you put the AC on top if the wheel well, it may need additional bracing to prevent crushing the wheel well liner.? ACs tend to collect water, and you put a pan underneath them to avoid leaking water from rotting the floor, and i dont know how youd do that above a wheel well. I've never heard of someone in this group installing an ac above a wheel well, so getting input from aliner could save you from having problems.


 

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Hi Gang:

Please let us know of the answers you get from technical support.

I put our replacement AC in the same hole as the old AC. My goals were 1) a quieter unit, 2) add braces to the wall that was starting to lean out and prevent the roof from closing. An added benefit is the dehumidifier setting on the AC. In the pictures of my rework you can see the diagonal braces I added to pull the roof back in line. Not easy to see are the braces under the frame the the diagonals depend on.

Dripping condensation shouldn't be a problem, window AC units are designed to drip out side, not inside your house. Our new AC doesn't even have a drip hole, the condensation is used to cool the hot coils.

You're welcomed to study the photo from our campers and ask questions. I've done a lot of work to keep our 2000 unit going.

Carl.

PS: the photos: /g/A-frameCamperForum/photo/124085/1485264?p=Created%2C%2C%2C20%2C2%2C20%2C0


On 5/1/2025 9:05 PM, Steve T via groups.io wrote:

If I were you I'd call aliner technical support and ask them how they recommend installing an air conditioner.? If you install it above the wheel well, you risk removing so much wall material it could make the wall too weak.? If you put the AC on top if the wheel well, it may need additional bracing to prevent crushing the wheel well liner.? ACs tend to collect water, and you put a pan underneath them to avoid leaking water from rotting the floor, and i dont know how youd do that above a wheel well. I've never heard of someone in this group installing an ac above a wheel well, so getting input from aliner could save you from having problems.


 

I installed the LG6000.? It does not have a drain.? All off the advertisement photos show a drain hole.? I called support and was told it was fine, for the reasons you mentioned.? It has a "slinger" to splash the water on the coils.? That said, I don't think anyone I have checked with has one without a drain hole.?


On Thu, May 1, 2025 at 11:00 PM, Carl via groups.io
<carl.blum@...> wrote:

Hi Gang:

Please let us know of the answers you get from technical support.

I put our replacement AC in the same hole as the old AC. My goals were 1) a quieter unit, 2) add braces to the wall that was starting to lean out and prevent the roof from closing. An added benefit is the dehumidifier setting on the AC. In the pictures of my rework you can see the diagonal braces I added to pull the roof back in line. Not easy to see are the braces under the frame the the diagonals depend on.

Dripping condensation shouldn't be a problem, window AC units are designed to drip out side, not inside your house. Our new AC doesn't even have a drip hole, the condensation is used to cool the hot coils.

You're welcomed to study the photo from our campers and ask questions. I've done a lot of work to keep our 2000 unit going.

Carl.

PS: the photos: /g/A-frameCamperForum/photo/124085/1485264?p=Created%2C%2C%2C20%2C2%2C20%2C0


On 5/1/2025 9:05 PM, Steve T via groups.io wrote:
If I were you I'd call aliner technical support and ask them how they recommend installing an air conditioner.? If you install it above the wheel well, you risk removing so much wall material it could make the wall too weak.? If you put the AC on top if the wheel well, it may need additional bracing to prevent crushing the wheel well liner.? ACs tend to collect water, and you put a pan underneath them to avoid leaking water from rotting the floor, and i dont know how youd do that above a wheel well. I've never heard of someone in this group installing an ac above a wheel well, so getting input from aliner could save you from having problems.

--
Don DeRyke
Sunrise, Florida

2009 Classic, 2020 Ford Escape, 2.0 liter EcoBoost, AWD.?
Previous TV 2015 Ford Escape 1.6 liter EcoBoost engine.


 

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Hi Gang:

I did make one change on our LG6000 AC. In the dehumidify mode the compressor and the fan cycle on and off. The fan cycling would wake up up, so I rewired the fan so I could switch it to "ON" continuously. Now when the compressor? cycles, (and it does often for a few minutes) we don't notice it.

Also it would have been much easier to add the fan switch before the unit was in the wall. I had to add an access panel on the top of the outside.

Carl.

On 5/2/2025 9:29 AM, Don DeRyke via groups.io wrote:

I installed the LG6000.? It does not have a drain.? All off the advertisement photos show a drain hole.? I called support and was told it was fine, for the reasons you mentioned.? It has a "slinger" to splash the water on the coils.? That said, I don't think anyone I have checked with has one without a drain hole.?


On Thu, May 1, 2025 at 11:00 PM, Carl via groups.io

Hi Gang:

Please let us know of the answers you get from technical support.

I put our replacement AC in the same hole as the old AC. My goals were 1) a quieter unit, 2) add braces to the wall that was starting to lean out and prevent the roof from closing. An added benefit is the dehumidifier setting on the AC. In the pictures of my rework you can see the diagonal braces I added to pull the roof back in line. Not easy to see are the braces under the frame the the diagonals depend on.

Dripping condensation shouldn't be a problem, window AC units are designed to drip out side, not inside your house. Our new AC doesn't even have a drip hole, the condensation is used to cool the hot coils.

You're welcomed to study the photo from our campers and ask questions. I've done a lot of work to keep our 2000 unit going.

Carl.

PS: the photos: /g/A-frameCamperForum/photo/124085/1485264?p=Created%2C%2C%2C20%2C2%2C20%2C0


On 5/1/2025 9:05 PM, Steve T via groups.io wrote:
If I were you I'd call aliner technical support and ask them how they recommend installing an air conditioner.? If you install it above the wheel well, you risk removing so much wall material it could make the wall too weak.? If you put the AC on top if the wheel well, it may need additional bracing to prevent crushing the wheel well liner.? ACs tend to collect water, and you put a pan underneath them to avoid leaking water from rotting the floor, and i dont know how youd do that above a wheel well. I've never heard of someone in this group installing an ac above a wheel well, so getting input from aliner could save you from having problems.

--
Don DeRyke
Sunrise, Florida

2009 Classic, 2020 Ford Escape, 2.0 liter EcoBoost, AWD.?
Previous TV 2015 Ford Escape 1.6 liter EcoBoost engine.


 

Wow!
The wall is probably as solid as a rock! This gives me ideas on the portable potty, too! Looks like you had to fabricate items from scratch, I can do that… I think!
Thanks! RY.


 

I’ll call them. Good to get their input.?

Thanks for offering the advise.
RY


 

I just talked to Kevin at ALiner.
He says the wall rear of the entry door, inside the cabinet is the traditional location for the A/C install.?
He said any other location would be a special custom install request by a customer on a new build.?
I told him that I had purchased the “kit”.?
He didn’t have any additional advise.
He was very pleasant about what he could share.
RY


 

Were you going to install it in the traditional way, or down lower?? Did you get install instructions with the kit?
?
On Fri, May 2, 2025 at 08:23 AM, Ramon Yanez wrote:

I just talked to Kevin at ALiner.
He says the wall rear of the entry door, inside the cabinet is the traditional location for the A/C install.?
He said any other location would be a special custom install request by a customer on a new build.?
I told him that I had purchased the “kit”.?
He didn’t have any additional advise.
He was very pleasant about what he could share.
RY