Urethane Pads replace AC Side Panels
Jul 10 '02
The Bottom Line Insulating, inexpensive, easy to use foam panels reduce noise and vibration. Why spend loads of money on a new AC when you can squeeze another year from your old one?
I did what any other homeowner would do. I covered it with duct tape, the handyman's friend
It's spring or, more likely, the first hot day of summer, and you drag your window AC unit out of the attic. Immediately you notice a problem. The accordion like, plastic side panels on your old one have disintegrated. Is it time to spend the big bucks for a new unit?
In my opinion, "Ten Tips on Buying a New AC," I explain how buying a new unit can save you money. However, perhaps your unit has an acceptable Energy Efficiency Ratio (EER) or maybe you just can't afford a new unit. I was in that situation myself last year. Naturally, I did what any other homeowner would do. I covered it with duct tape, the handyman's friend.
Well, I have to tell you that the duct tape's performance was less than stellar, so with a little spousal encouragement, I headed for the local home-warehouse. I intended to buy a new folded plastic insert, like the old one. However, when I got there, I found a new product that intrigued me, a crinkle-cut foam pad. Urethane foam, it's not just for breakfast anymore.
The pad I got was from Frost King, and cost $11, although I am sure there are other brands that work just as well. Inside the pack were two 9' wide, 18' high, 7/8' thick panels. They are crinkle-cut, like thick French fries, and made of black urethane foam. There are also a couple of black plastic channels, which I did not use.
First, you remove the sliding holders that hold the plastic panels, unbolting the panels from the AC unit. Put the screws away somewhere safe, you're bound to need them again someday. Then use the holder as a guide to cut a panel to the correct height. The crinkles run vertically. The foam cuts easily with a sharp, utility knife and a straight edge, but so do your fingers, so please be careful. Remember to put cardboard or waste wood underneath to avoid damaging your floor. Cut the foam about 1/8 too long for a nice snug fit.
Measure the width of the opening, and subtract the width of the AC unit. Divide the resulting measurement in two. My window opening was 28 1/2 inches, the AC unit was 20 inches, leaving me a 8 1/2 inch opening to fill, so I needed two pieces, at least 4 1/4 inches wide. Now cut the foam down the first vertical groove that leaves a piece that is BIGGER than your measurement. For me, that was exactly 4 1/2 inches. This was lucky, because the pads are 9 inches wide, so one cut gave me both pieces. It also means that for me, one package will fit two AC units.
Now slide the two, foam pieces into the holders, crinkle side facing inward, and slide the holders onto the AC unit. Finally, pop the AC unit into the window. Total job time is about 10 minutes. There are black plastic channels that glue to the side of the AC unit for a better seal. There is only enough channel to do one window, so I did not bother using it.
The black foam is quite nice looking, although it does not match the AC unit. It certainly looks a lot better than the duct tape did. It fills the opening snugly and needs no extra sealing. The thick foam cuts out a lot of the outside noise, and the AC unit appears to be running quieter with it in place. I can't prove it, but the foam has to be better insulation than the old thin plastic panels. We have already weathered a couple of major thunderstorms with no noticeable problems.
The package claims that you can even use the foam as additional insulation for existing panels. I am not going to drag an AC out of a window to try it, but maybe next year. As it is, at $5.50 a window, it is a viable alternative to buying a new AC.
See also:
Panasonic AC CW-C60YU: http://www.epinions.com/hmgd-review-350-D4BACF6-39353C77-prod1
Electrostatic Filters: http://www.epinions.com/hmgd-review-222F-F57D038-39523809-prod5
Ten Tips on Buying a New AC: http://www.epinions.com/hmgd-review-2668-DE699F9-3936C939-prod1
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