RV AC Unit Modification for Better Efficiency and Noise Reduction

Introduction

• Objective: Modify RV AC unit to increase efficiency, output, and reduce noise
• Types of AC units covered: Open design and framed-out metal wall designs

Initial Steps

Removing Panels and Framing

• Step 1: Remove plastic panels and framing from the AC unit
  • Pop out removable panels
  • Remove screws holding the rest of the framing
• AC Inside Look
  • Cold Side: Blower fan side, blows cold air into ducts
  • Warm Side: Warm air return side

Problem Identification

• Inefficient design: Cold air mixes with warm air, reducing efficiency
• Need to separate cold and warm sections with insulation boards

Modification Steps

Preparation

• Disconnect Power: Shore power and 12V battery
• Remove Control Box: Unscrew and drop thermostat control box

Removing Metal Divider Wall (if present)

• Remove Metal Framing and Divider Wall: These are barriers to efficient air flow

Sealing and Insulation

• Housekeeping: Remove loose metal tape, reapply new tape to seal air leaks
  • Seal around ducts, blower fan port, ceiling edges, and warm air return

Building the Baffles

Baffle Construction

• Measure and Cut Board: Measure and cut the insulation board for baffles
• First Baffle: Wall between cold and hot side
  • Measure: From duct to other side (~14.5 in), make it 1 in short for bottom piece
• Second Baffle: Direct air from blower fan to ducts
  • Measure: From top of the duct to blower fan port (~8 in wide, 6 in height)
  • Cut side pieces for both sides of the duct

Fitting and Notching

• Test Fitting: Ensure pieces fit well; tape temporarily
• Notch for Bolts: Mark and cut notches for bolts if metal wall design exists
  • Notch to accommodate bolts for metal framing
• Top Baffles: Tape top baffles in place

Final Assembly

• Floor Baffle: Measure and cut board for floor baffle (~9.5 in width)
• TP Baffle: Build a TP shape baffle to direct air efficiently
  • Pieces: One 4x8.5 in, another 3x8.5 in; cut at 45° angles
• Install and Tape: Install floor and TP baffles, tape all seams and joints

Reassembling the AC Unit

• Reinstall Divider Wall: Tape permanently, install floor baffle
• Reattach Framing and Control Box: Secure control box with metal tape

Final Notes

• Losing Dump Vent Feature: After modification, dump vent feature is lost
• Considerations: Might cut interior framing on cold side for easier installation
  • Could save time but require careful consideration

Conclusion

• Outcome: Modified AC unit should be more efficient and quieter
• Tip: Further customization may be needed based on specific AC unit design
• Closing: Stay safe and enjoy your camping!