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AC Boxes Made Easy (to understand and build)

hoosierdaddy

Active member
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Attics are the hardest place to get things squared away, although the most stealth.

For an attic box, first thing is to make sure you have it insulated really well. I would suggest lining the inside of the box with Dow insulation board. The aluminum surface of one side provides adequate reflective surface for the inside walls. No paint of mylar needed.

Also, where you get your air can be important in an attic where it gets brutal hot. If the attic is a full gable type, you could cut two openings in each end of the attic and place a gable fan at one of the openings. They sell gable vent covers at any HD or Lowes that match the siding of your house. I know this sounds daunting, but it would be the best thing to keep the attic temps in check. To save energy you could put a thermostat controller on it (not very expensive) to only kick it on when the temps get real hot.

If you don't have the ability to install any flow-through air movement with a gable fan, then you want to run a duct from the intake of your ac unit to where the attic takes in air. This will most likely be from the soffit area of the roof (lowest point) at the overhang outside the building. You can see little holes in the horizontal soffit, and that is where the roof breaths. That is the place to find the coolest air possible. Just have the end of the intake duct laying on top of the soffit from above (you may have to move insulation to find this soffit and the holes). I suggest using the largest duct you can find for this, at least 6" but better 8-10".
This duct would lead back to the box that surrounds the intake only.

For the exhaust...IF you do have good flow through ventilation in the attic, you could just let the back of the unit exhaust into the attic itself. You could fashion a partial box around the back just to direst the hot air where you want it..and not blowing hard on rafters and such.
The flow through air will not only allow you to keep the attic cooler, but it will help you shingle to live a much longer life than they would in a no air flow attic.

If no air flow in attic, then you need to enclose the back end of the unit and exhaust the heat one of two ways...
Run another duct from the exhaust back to the soffit on the other side of the attic. You could mount it onto a soffit piece if you have your carpenter on...but you could also just lay it over the holes as you did on the intake side.
OR...you could get real fancy and cut a roof hole for an exhaust stack. These are also cheap and easy to find with full instructions on how to....but again you need to have your carpenter on for that.

After you have your ac figured out and working, you will still need to exchange air in the box. For this I have intakes a couple feet above the floor on one side. Having ac it will take a small fan and very little movement of air to keep things fresh, but it needs to be there. Again, if you have your attic temps taken care of with a gable fan, then you can just suck air in and blow it out into the attic. If not, then you will need separate ducts for the air intake and exhaust set up like you did the ac ducts and getting air from the soffit area.


I used to also think about my ac and the cool air from the top, since cool air sinks....but, I have a different thought about it all now. The root zone is where the cool is most important. If you keep the roots nice and cool, the veg part of the plant can take very high temps with no problems..just like in nature where the ground has a natural cooling and constant temp, and the ambient above can get quite brutal in the mid-summer sun.

The last pic I posted shows the ac unit in the lower right of the shot. It sets on the floor of the cab in the next chamber. I would suggest you set your box up in a similar fashion. You will need a rectangular hole in one side of you box at the bottom just large enough to insert the front of the AC unit into the hole.

This is a lot to absorb, so if there is anything that you are unclear on, don't hesitate to ask.
 
hey i just want to say thanks for this write up. becasue of this my portable ac will be going on craigslist and i'll be getting a larger wall unit that i will mod.

dont understand why my portable must not recirculate the air from the vents but exhausts the stink air out my exhaust. stupid stupid design!
 

Medgirl

New member
Thanks for the detailed information.

I do have a gable roof with 2' x 2' air vents on each end of the attic and vent that runs along the peak. Also soffit along the entire roof edge. No fans though.

I'm thinking of bringing the air in at one of the vents or at the soffit and just exhausting into the attic.

I don't understand the part about a separate vent for exchanging air in the box. Wont the a/c intake and exhaust exchange plenty of air in the box already?
 

hoosierdaddy

Active member
ICMag Donor
Veteran
You have the perfect setup for an efficient attic room. I would highly suggest looking into a gable fan from HD or Lowes, or even on line. You can find them cheap and they can be hung from your rafters with nails. They usually will have little metal straps with holes you can nail.
Putting one just outside of one of the gable vents and directing the flow of air out will greatly lower the temps in the attic. Helps greatly on the life of the shingles as well.
If you do this, you could for sure just intake and exhaust air to and from the attic space.
Also, check to make sure that both vents have cut-outs and actually flow air. Sometimes they only cut one side and leave the other solid.

The ac unit has a separate cold air flow. All the cold side does is cool and recirculate whatever air is in the grow area. It does not add to or take away any air. All of the air exchange for the ac unit is for the hot air side.
So, you need to have regular intakes and an exhaust fan to change the air in the box. Although with it being kept cool, you will not need to move as much air as a non ac box would require. You want to have negative air pressure in the box so that you can scrub the air with a scrubber. If you have a small say 4" duct scrubber above the lights, it will keep the pressure negative and clean the air. Just exhaust into the attic.
You need two 4" holes for intake, and I would suggest these just about 24-36 inches from the floor, (if you put the ac on the floor). If you decide to put the ac higher, put the intakes down low. Although the most efficient use of the air is to keep the cool air down low and scrub the hot air above the lights.


42896ac3.jpg

Using the above sketch, you could take the hot air exhaust duct and hang it up close to the gable vent, and just take in air from the attic without boxing the intake up. Also, there will be condensation coming from the ac unit. Many smaller units will have evaporative type water removal and there are no drains or tubes. But larger units will have a port for the removal of condensation build up. You will need to run a hose from that drain to a hold of some sort...possibly down to the lower level and a tank or cooler or something that has a bit of size to it. An ac unit can create a surprising amount of water especially in a higher humidity area.

Like I said, the air in the grow room is separate from the hot air and should not mix together at all. SOME units will have a fresh air vent that can be opened that actually allows these two air flows to mix and allows some of the ambient air in to come into the cool air side, and some of the cool air will go out the exhaust. However, you do not want this situation to exist because with air going out, so does odor. If the unit you have or want has a fresh air vent, it would be wise to take the back of the unit off (just a few screws) and you should be able to see the vent. It may look like a plastic flap. You want to glue that shut, and caulk it so it is air tight. Take it out of commission forever the best you can and seal it up.
 
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Gold123

Member
Thanks for the detailed information.

I do have a gable roof with 2' x 2' air vents on each end of the attic and vent that runs along the peak. Also soffit along the entire roof edge. No fans though.

I'm thinking of bringing the air in at one of the vents or at the soffit and just exhausting into the attic.

I don't understand the part about a separate vent for exchanging air in the box. Wont the a/c intake and exhaust exchange plenty of air in the box already?

There are some pretty cool solar powered vent fans out there but they are in the $250 and up price range, HD, Lowes and Costco on line
 

Medgirl

New member
The gable vents are real I have been in the attic.

So your saying I can run exhaust out the gable vent and just intake directly from the attic as in your picture? But I need a separate intake to the grow area? (but not directly from the attic, from somewhere cooler?)
Will the grow area suck this extra intake air in passively through the duct or does it have to be forced in with a fan?
 

Gold123

Member
The gable vents are real I have been in the attic.

So your saying I can run exhaust out the gable vent and just intake directly from the attic as in your picture? But I need a separate intake to the grow area? (but not directly from the attic, from somewhere cooler?)
Will the grow area suck this extra intake air in passively through the duct or does it have to be forced in with a fan?

You need to exchange the air in the attic faster than ambient air flow, otherwise the attic will heat up and the air conditioner will have to work overtime.
 

hoosierdaddy

Active member
ICMag Donor
Veteran
You need to exchange the air in the attic faster than ambient air flow, otherwise the attic will heat up and the air conditioner will have to work overtime.
Exactly, that is why I recommend a gable fan to keep the air in the attic as fresh as possible.

The best thing in this case would be hanging the end of the hot air exhaust right behind the gable fan which would push the hot air right out of the attic. That plus all the other air the gable fan is pulling will keep the attic relatively cool and much closer to outside ambient.
Then you could actually use the air from the attic for both intake of the ac unit and intake of your cab.

You would probably not have to go get cooler air from the soffit with a duct, just cut light trapped holes in the box. Then a scrubber above the lights would be sucking air and blowing it out via another fan that exhausts out into the attic.
 

Medgirl

New member
Thanks for all your help. I just think that in summer when it's 95F and 75% humidity that sucking in attic air to the box would be a bad idea because the attic air would be much hotter, even with a gable fan.
 

hoosierdaddy

Active member
ICMag Donor
Veteran
If it is 95degF outside, that is the coolest air you could find, unless you plan on taking it from the house air. Which could be done, since you are not going to need a whole lot of air flow to keep temps down using the ac unit. I think a thermostat would be in order to only run air in and out of the box when the temps above the lights get to a set point.
And yes, the attic will be hot air too, but not much hotter than ambient if there is good air flow.
 
D

dubdi3mond

if i was to make an a/c box for a window unit and put it directly in the room itself not through the wall would the exhaust leak smell or would it just be the air brought in by the intake that is exhausted? thanks!
 

hoosierdaddy

Active member
ICMag Donor
Veteran
The ac unit only take in air at one place...the vents that would be outside. When you box up the intake, that air goes through the hot coils and then is exhausted out. You need a separate box to enclose the exhaust and duct that hot air out.
As long as the fresh air vent is closed surely, then no odor will escape through the hot air exhaust of the unit.
Now, if you don't box up the intake and get air from somewhere besides in the grow room, then yes..the exhaust will carry the odor out with it.
Don't starve air in or out. The larger the ducts, the better.
 
D

dubdi3mond

The ac unit only take in air at one place...the vents that would be outside. When you box up the intake, that air goes through the hot coils and then is exhausted out. You need a separate box to enclose the exhaust and duct that hot air out.
As long as the fresh air vent is closed surely, then no odor will escape through the hot air exhaust of the unit.
Now, if you don't box up the intake and get air from somewhere besides in the grow room, then yes..the exhaust will carry the odor out with it.
Don't starve air in or out. The larger the ducts, the better.

thanks bra, that was the answer i was looking for
 
D

dubdi3mond

another quick question, what do you guys do to accommodate the condensation from the a/c unit? I imagine you could put some sort of catch under the unit and the drain holes but I was just wondering if anyone had come up with something even more simple?
 

hoosierdaddy

Active member
ICMag Donor
Veteran
Small ones simply hold the water in a catch and depend on re-evaporation. These will have no drain ports.
One with a drain can be plumbed to anywhere or anything you want. But if you don't run a drain tube of some sort, you do want to have a can below the port.
 

Lurker90

Member
hey i was wondering if anyone has had any experience with building a box for a larger unit? i was wanting to use a 25,000 btu ac and hook up a 6 inch duct line for the intake and a 10 inch duct line for the exhaust piped into my already existing exhaust... should that work fine or would it get too hot?
 

hoosierdaddy

Active member
ICMag Donor
Veteran
If you use 10" for exhaust, use at the very least a 10" for intake..better off with two 10" pipes for intake. The first thing that has to happen is getting enough air to satisfy the system and you can't do that if you choke down the pipe sizes in or out.

Also, if you are going to pipe into your exhaust, that final exhaust that you connect to needs to be large enough to handle the extra air flow. Better to let the exhaust duct find an exit by itself and not taking it into another line.
 

Lurker90

Member
what if i do a 12 inch intake and exhaust for the box and pipe it to a 12 inch exhaust that has a 10 in max fan pushing through it
 
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