Dan O. -- Thursday, 8 June 2001, at 6:58 p.m.
: What's the best/easiest way to reproduce the
: necessary window frame-like structure in a new
: wall cutout?
That is more a question for a home contractor (someone that does home renovations or construction) than for an appliance professional which deals with the appliance itself. Load bearing wall considerations are likely necessary as well as possibly building permits.
You can read some installation instructions at the page linked below.
: I would like to install a window unit through the wall.
My main suggestion is to buy the type of model designed to be built in and not just a window unit. That will save you lots of headaches, both now and down the road.
Most window air conditioners have side air louvers which need to be totally open and unobstructed for proper operation. In many cases the walls of a house are so thick that those side louvers would be obstructed if mounted through the wall. ANY reduction in air movement through the air conditioner will reduce cooling ability, increase energy consumption and likely lead to premature component failure of the fan motor ($$$), compressor ($$$+) or both.
Air conditioners designed to be mounted through the wall usually have both intake and exhaust vents at the rear so wall thickness is not a problem. They are also usually designed to be mounted into a stationary sleeve so the unit itself can be easily removed for service, which should be done at least every 3 years. Failure to properly maintain an air conditioner will also reduce cooling ability, increase energy consumption and lead to premature component failure.
However you go about it, I *strongly* suggest you make it so the unit can be *easily* removed afterward for service. But make sure it isn't an easy access point for burglars.
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