I,ll be going to boat today,get you size!Friend did the same on his and cut in a small round acces port just for hose ,older Catalina so didnt mind cutting in to it.@DJN51 ingenious
I have a solar vent in the front near the v-berth and it is almost dead. I might be able to hook a hose out that hole and keep the ac under the table?
Do you know how tall your unit is?
Is there anything that says the cowl has to be hard? Could you get the same performance from a soft form that would fold and stow in a locker for when you're sailing? Maybe make a sandbag/lead shot rim to hold it in place around the hatch opening? Something like a wind scoop for the AC.I guess the final question is do I want to use furniture grade plywood and varnish... or do I want to paint.
You probably don't want it in casters anyhow. To much rolling around in a marina or at anchor can be annoying.I had to remove the casters to let it fit under the table
This particular unit has a built in condensation function and vents moisture out the vent hose. There is a plug in the bottom of the unit to drain it but the owner's manual says that it is to be used only if the unit stops cooling. Normally it should not need draining. I guess that is another thing to keep my eye on.By the way, if the portable model can fit and is more convenient that in the companionway (seems to me it would be) - but you are worried about condensate into the bilge, you could get a 120V condensate pump and route the hose out wherever the A/C exhaust exits, or maybe into your sink. You will need 120V anyway. They are only about $40 or $50 at home improvement stores, and there may be smaller one that are less. They do make some noise for maybe 30 secs when they are triggered to pump out.