Quote:
Originally Posted by Wavery
The whole purpose of those baffles is to keep rain water and debris out of the cabinet when the A/C is not in use.
There is no real need to cover the center part of the grille because the lovers point down and prevent most water intrusion. If a small amount of water does get in, it's not harmful because everything inside the cabinet (including the 2 vertical air separator pieces was covered with a coat of fiberglass (I used epoxy resin for ultimate water resistance).
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So if that's the whole purpose of the baffles, I wonder then if they can be avoided simply by using a louvered vent (like what you used in the center on the outside, which I presume was simply the one installed by the factory) that is larger, wide enough to cover your enlarged hole. Obviously, it would have to be sourced, but there may be something out there suitable. Dimensions wouldn't have to be exact. The height could be a little bigger of course, and the width could vary as the size of the enlarged hole probably has some flexibility (in terms of making it slightly smaller, if necessary).
Dave