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We are thinking about upgrading our 5K BTU A/C for something a little larger.  Frigidaire, the maker of our current A/C makes an 8K BTU that's a little wider but I think may work with a little modification of the cabinet it sits in.  Anyone else do this?

The 5K BTU just doesn't keep up in the hot TX summers.

Matt is right – looks like it's going to be the 6500 once we got the old one out – which was a definite chore.  The A/C sits on a piece of sheet aluminum that is folded up on the sides to make a sort of drip pan.  The front of the aluminum was siliconed to the back of the cabinet rail. 

The only way to get the A/C out was to dismantle the cabinet.  And the cabinet is not screwed together – oh no, nothing that simple.  The bottom is 1/8″ luan that was stapled to the cabinet.  Removed that – no screws holding the cabinet face on – oh geez, how is it held together?  Turns out it has the wood staples that look like a cross between a staple and a biscuit holding the stiles.  We were able to bang them out from inside the cabinet right next to the A/C – remember we have the bottom off at this point.  Then pulled the bottom rail off – when we found the silicone.

The hole is framed out with what looks like maybe 2×3's.  Tomorrow's job will be to see if it's just framing or if the verticals are actually jack studs above the window.  If it's just framing we are in good shape and will only have to widen the hole less than 2″.  If they are studs, we will have to think it through a little more.

One thing I still haven't figured out is what we are going to do about the outside shroud.  The top vent is no issue, it's plenty wide enough.  But the side wall shroud pretty well just fit around the 5K unit.  Oh and they added an extra piece of expanded metal on the back of the A/C for protection – we will have to get some more cut.  We are talking about getting some aluminum stock and building a frame around the back of the A/C.  The plastic shroud was held on with about 18 hex head screws with butyl rubber tape as a gasket, then the edges caulked.  As long as we can protect the hole and the edge of the A/C while allowing for drainage (holes in the bottom), we should be good to go.

And just to add to the fun, I found 2 wasp nests on the top vent and grating – I'm not sure how we are going to be able to keep them out in the future – will have to climb the ladder and see how the top vent cover is configured – I know there is a gap between the cover and the edge of the trailer.

I thought to take some pictures tonight after we had everything dismantled.  I will try and post them tomorrow.  I also need to take some pictures of the dismantled cabinet before I forget how it all went together

If I may make a suggestion – why not install a 9200btu roof mount A/C instead?  I know at least on the 19' and up, the roof vents are pre-wired for an A/C.  The 1500btu difference may not make much of an impact.  At least if you had the rooftop unit, you could do one of several things – use the factory 5k on not-quite-so-hot days, use the rooftop on hotter days (do not recommend using both at once due to startup amperage of two A/C's, though there are rooftop A/C's that draw a little over 10A running), simply use the rooftop A/C and keep the other one intact "just in case," or install a rooftop A/C, remove and block off the factory A/C unit, and make a storage compartment in the empty space.  I'm only suggesting this because I don't feel that the slight increase in BTU's will help tremendously, especially when camping in HOT weather.

Steve – you may have the right idea.  At least I'm finding out about the construction of our trailer.  And even though it's made with entry level materials instead of high-end, it's been put together really well.  It's taking a lot of effort to get everything apart but we are there and have started expanding the hole for the new unit.

Last year, the A/C just about kept up at night but not really during the day time, especially if our site wasn't shaded very well.  And since we are already hitting the 90s (93 today, I think it was a record), I want to be prepared for what will come.

Wow a 13,500 – you may actually get frozen out with that much!

Progress has been slow because I'm finishing up a term in school – going to graduate school and have only had an hour here and there to work on the trailer.  We've got the framework pretty well figured out and have test-fit the A/C – we had to do some modifications on the hole in the side of the trailer.