How to find very small window frame for air conditioner?

I want the smallest possible hung-window frame that can hold my window unit (air conditioner).
Window frame size would be 20.5″ W x 16″ H.
Normally the bottom rail of the sash holds in the air conditioner’s top guide.
Instead of a complete sash, only the bottom rail would fit above the air conditioner.
(I am using terms from https://www.salisburyjoinery.com/blog/parts-of-a-window-explained > bottom rail, stile, jamb)
There are two ways this bottom rail could be fabricated:
– Fabricate a bottom rail from wood.
– The window manufacturer cuts a length of bottom rail to fit across the left & right jambs.
Has anyone installed an air conditioner like that?
How do I find a window-frame manufacturer that would build such an odd window frame?
How do I go about locating a window installer?
Would the window installer know where to get a custom frame like that?
The window frame will go into an existing blank wall with 2×4 studs, 1/2″ drywall, and stucco siding.
I am not installing a through-the-wall air conditioner because:
– the smallest through-the-wall unit is 8,000 BTU
– I already have a 6,000 BTU window unit
– this small room needs only 3,000 BTU
I ran the 6,000 BTU window unit in the room’s only window last summer.
On the hottest afternoon, it cycled off half the time.
So I figure 3,000 BTU would be enough.
Replies
If I understand the above, you want to put a “window” ac in a wall.
You would not have a sash above?
So, you are putting in a “window” ac through a wall….
Yes?
So a single “pane” (opening) is what you need to build. Slanted bottom sill, 2 sides and a top. Would you be pulling this ac out seasonally?
Thank you for your response calvin.
Yes, I am putting in a “window-unit” AC through a wall.
The AC will stay in the wall year round until it needs service or replacement.
The eventual replacement AC would be smaller.
We have casement windows. For many years we cooled the house with one larger window unit.
Since casement windows don’t allow (opening out) just placing the ac and closing down the upper sash (non existent), I made up a panel that screwed to the stops of the existing casement frame.
So, removed the sash, screwed the panel (1/2 ply) to the opening, the ply was reinforced at the top of the opening with a 2x 2 across…..
Every year, remove the sash, fasten the plywood “frame” in the opening, slide the ac unit in the hole……
Well I got older and the ac and sash got heavier.
We have now added an exterior mini split.
Foe over 20 years we cooled this whole house with that yearly moving arrangement. House is pretty energy efficient and in the woods, so summer shade.
The main worry through those old times was dropping the rather large casement sash and maybe some concern a bird would fly in during the process.
I had the AC window unit in the window last summer.
But that room only has one window.
So now I want to put the AC window unit through the wall instead of the window.
That way I can open the window over night when it's cool.
check with companies that repair windows, shower doors etc. in your area. Also lumber yards. They may know a custom window or door builder who could make you the frame you need.
Thanks for the suggestions 1095mike. This frame might be simple enough that it doesn't need to be made in a factory.
It is assumed you understand that cutting a hole in a wall requires understanding of how elements of that wall hold things above.
A window frame is not going to take the place of a header to spread loads from above around your new opening.
One option that may make more sense is a mini-split, which would let you use a small hole which can be sealed much easier than a window unit.
It might cost more for a 6kbtu, but you could end up with a heat pump, in addition to the air conditioner, and not spend much more than paying a qualified carpenter to properly frame the opening and fabricate/purchase a frame.
Hi unclemike42,
Three estimates for a mini-split were $5,000 give or take.
They said it cost so much because running wire from the far-away circuit breaker and routing over many corners.
Also, routing external conduit over many corners and walls reduces aesthetics.
The AC window unit through the wall would be on a non-weight bearing wall i.e. gable wall on single-story house. And I can plug it into an existing wall outlet.