My problem is a "thru the wall" ac I have in my bedroom. There isn't a window in the master bedroom, only a 6' slider and a smaller window in the master bath so I had to install one of these. I like it since it's quiet and makes the room COLD but in the winter I noticed that condensation was forming on some of the interior metal surfaces. The problem is the sleave the unit slides into, which is metal. The instructions said to install it as close to the finished surface as possible so the weight would be on the framing. So as warm/moist air hits the small area of the cold metal box, it forms condensation and causes small drops of water that'll run down the wall when it's really cold.
Now, I was thinking of a solution to this and have come to the conclusion I need to insulate the exterior or interior portion of the ac. I was thinking of using some 3/4" thick polystyrene to make a box to slide over the exterior of the ac and use a cover over that. I'm hoping that'll keep the metal outside a little warmer and prevent the condensation. I'm afraid that may lead to corrosion of the ac, possible critter homes, and flat out not work. I thought about an interior cover but I'm not sure that'd work and only trap the condensate inside the cover and cause moisture problems without me seeing it, and I'm sure the wife wouldn't like the look.
So, any suggestions on this one?