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I replaced the 5000 BTU A/C that came with my 16BH with an LG 6500 BTU unit.  With our Texas weather, we needed the little extra oomph.  Yes, I would have liked to go larger still, but that would have meant going to a roof mount and I don't think that would have worked with our unit.  It would definitely have been a head-knocker for DBF.

We had to do major modifications to the cabinet – we ended up building a new one from scratch -

We did have to make the whole through the wall bigger and we were worried how to finish off the outside.  Fortunately, KZ started putting larger units in the Classic line and have a plastic shroud to fit.  However, we had to account for an almost 1 inch difference in the depth of the units.  I hit upon PVC trim pieces to make a filler frame between the aluminum skin and the shroud.  I used double layers of butyl rubber to give enough flex to seal against the aluminum skin, then used silicone grout on all the seams:

We need to work on our grouting skills somewhat

Mine was the Frigidaire 5000, and Conn's carried the larger, but it was much larger.  The LG 6500 was the closest in size to the 5000 we took out, at least where we are located.