How to build a custom AC unit cover?

Question

I have an AC unit on my apartment balcony and wanted to create a box around it with a front grill to allow airflow. Ideally it would be black in Colour and strong enough to place my herb planter box on top. There’s a pipe that runs close by that would need to be factored in to the cutting of the materials, although, I’ve only got a simple tool box. The dimensions are roughly 130cm length, 90cm height, and 55cm depth. The pipe on the right is about 15cm. Any suggestions on where to start?

MitchellMc · Answer

Hi @Zonal,

I thought I'd just point out that we have air conditioner covers available on the Bunnings Website. If one suited the space, it might save you some work.

Mitchell

JacobZ · Answer

Hi @Zonal,

Welcome to the Bunnings Workshop community, it is wonderful to have you with us.

The first thing to check before designing anything is the clearance requirements for your specific AC unit. Most manufacturers specify minimum gaps around the sides and top to allow proper airflow and servicing. If you enclose it too tightly, even with a grill, you can reduce efficiency or risk overheating.

Once you have those clearances confirmed, you can design around them rather than the exact unit size.

Start by building a timber frame, that sits outside those required clearances. You can use H3 treated pine, such as this

https://www.bunnings.com.au/70-x-35mm-outdoor-framing-h3-treated-pine-2-4m_p8032103

and

https://www.bunnings.com.au/zenith-10-8-x-75mm-galvanised-countersunk-rib-head-timber-screws-50-pack_p2420885

to build your frame.

From there, you can clad it with horizontal or vertical timber slats on the front and sides, spaced to allow consistent airflow while still giving you that screened look. Something like

https://www.bunnings.com.au/90-x-22mm-decking-h3-treated-pine-l-m_p8032580

would work well. They can be fixed to the frame using

https://www.bunnings.com.au/titan-10g-x-50mm-304-stainless-steel-wide-head-decking-screw-100-pack_p0658856

.

Given you want it black, you could simply paint the frame and slats using 2-3 coats of a suitable exterior paint such as Dulux Weathershield or Wattyl Solagard, that is tinted to the colour of your choosing.

Now, it would be fine weight wise to support a few lighter planter boxes it is worth reconsidering putting plants on top for two main reasons. AC units throw off a fair amount of heat, so placing pot plants directly above can stress the plants and trap heat around the unit. Realistically, it would be better to look at other locations for your plants to ensure their health, as well as the efficient function of your air con.

You might like to check out @homeinmelbourne's condenser screen as a good example of what is possible.

https://www.workshop.bunnings.com.au/discussion/144038/air-conditioning-condenser-screen

Let me know what you think and if you have further questions, please don't hesitate to ask.

Jacob