Been working on this for couple weeks.  My Dad died right after I got started so it got put on back burner for a bit.  But for me best therapy is being in shop so back to work.  Previously I made a exhaust fan enclosure to fit this same window.  Used a attic fan for the job.  Worked great!!!  So good it would pull the finish into what looked like waves across a flat piece.  Also at 1600 CFM it would pull door open.  If closed you had to be careful you didn't get your head knocked open.  So I found this smaller fan with a supposed 650 CFM.  Fart fans usually come in at 100 CFM and for me that is just not enough.  This unit came complete with louvers and a speed control.  Didn't cost extra for the speed control for same unit so hey why not see how it works?   Tried it and it is NOT going to work for me.  Buzzes at anything under medium.  Opened the unit up and the internals are cheap.  Doubt they would last long.  Might use the controller on something else but not for this project.
 

Exhaust Fan

 

 

For this build I opted for two pieces.  One piece replaces the old window on top and fills the channel so it is 3/4 thick.  This brings it flush to the track on outside and flush to the inside track as well.  Then centered up the fan and made a hole for fan.  Next I built the cabinet and then dry fitted.  Drew the outline of the hole on the back and took back to shop.  Screwed the two pieces together on those lines and routed out the hole in the cabinet.  

 

The bottom has a 2 inch thick piece of insulation board built into the back.  When cooler weather comes I can open the future door and insert a 2 inch piece of insulation board behind the door.  Then unplug fan.  Keeps cold air out and no accidental fan operation.  Wiring is internal through the back insulation board with a hole to let the power cord come out the bottom and go to outlet. 

Fan can be turned on manually or use the timer program to turn on during the day.  Nice feature.  Had considered a thermostatic fan but though this would work better.   

 

Pictures of progress so far.

 

Window insert

 

 

Old sheet to be faux curtain same method as used on rest of cabinets in this room.

 

 

Operational fit.

 

 

Added storage.

 

Edited April 25, 20215 yr by Gunny

Gunny if you need more exhaust fans a heating air conditioning shop around here throws the ones they replace out back and are a give away item. Only some of the latest motors are combined with the thermostats. I had them leave my old unit here when they put in a new unit...and with a three speed motor I use the speed that works best  for where I installed the two I use. Both are squirrel cages so I can replace the air in here slow or fast.

 

1 hour ago, Smallpatch said:

if you need more exhaust fans a heating air conditioning shop around here throws the ones they replace out

That's what I've been using, although most are squirrel cage type which stick out into the room more.

Outside window view

 

 

 

 

 

Nice clean look. 

10 minutes ago, lew said:

Nice clean look. 

Thanks. Wife called to tell me I left fan on last night. LOL timer was set for 2pm to 3pm today.  Seems it works.   

We have used a whole house attic fan in 3 houses over the last 35 years.  They work great to cool down the house at night.  My rule is "anything less than 70 degrees ambient temperature and 70 degrees dew point"

 

 

You are getting quite the finishing area!

2 hours ago, kmealy said:

My rule is "anything less than 70 degrees ambient temperature and 70 degrees dew point"

That's a lot more comfortable than the berthing compartment on the 03 level under the #2 arresting wire and no air conditioning off Yankee Station.

Project completed.  Installed screen on door to keep bugs out and such.  Then installed door with two latches to keep it closed.

 

 

 

 

 

For winter I have this 2 inch thick piece of foam insulation that goes into the hole, then close door and unplug fan.

 

 

 

Fits right in with other cabinets.

 

Like the screen idea along with the insulation. I had wondered about winter weather and just some aluminum vents.

1 hour ago, Gerald said:

Like the screen idea along with the insulation. I had wondered about winter weather and just some aluminum vents.

 

I also have a false back on the lower side of cabinet that has same 2 inch insulation.  Used this on all 4 window unit builds so far.  My goal for this was easy in and out and no changing the windows.  Only had to remove the upper glass panel which I stored below the building in crawlspace with shop heater.  This way if I change my mind or when we sell the house less work to put it back.

Edited April 27, 20215 yr by Gunny