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If the AC needed an extension, why didn't you make the AC flush with the box? As you have it now it's sticking out into the very limited space you have inside that trailer. If you made the control panel flush with the box, you would get those inches back and not stub your toe on it.
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It's not an extension as in what you probably think it is. The exhaust vents through the floor so its a 90deg duct pretty much. I can't push it any further back due to the size of the exhaust port, its basically cut out almost to the frame already. Plus this is how they normally sit in the window and any further back and the power cord would be in the 2x2.
I have found there is one downside to this system, the need for a fan to make sure the cold air doesnt sit in front of the thermostat. But as long as I have a small fan going the air gets distributed fine. I'm going to experiment with attaching a ramp to try and force the air more upwards as well. I'll probably end up seeing about pulling it out and extending it or wiring in a house tstat instead of the one on the unit.
I ran it for most of the day yesterday and it kept the trailer really pleasant. It's still in the 80's here though so we'll see how it handles this summer. I will swap it out to a 10k if needed.
As far as the intake/exhaust mixing i've heard that before and its definitely a consideration. I may end up putting a piece of angle iron or something under the port or using a marine door I can keep at like a 45. I kept checking the unit now that I have the top on and it didn't seem to be having any issues I could tell.