Bosch Cool (2000)/4000/5000 Fast & Simple Window Hose Adapter (STEP file included)

Background

There are a lot of amazing and well thought through hose adapters for mobile air conditioners available, but these have quite long print times. I'm impatient and wanted something which is simpler, uses the available parts of my ac unit and prints (in comparison) fast. So I created this minimalistic approach for attaching the hose of a Bosch Cool 4000/5000 and probably also 2000 to a window.

Parts

Depending on the kind of setup, you at least need…

• 2x M5x16 screws for the grip
• 4x M5x20 screws for the adapter plates 
• 6x M5 washers
• 6x M5 nuts

Additionally, my setup consists of…

• 1x 3mm thick sheet of transparent acryllic glass
• 1x small part of a mosquito net (to ensure no critters get into the hose, I used tesa Standard)
• [optional] 1x UV protection film
• 5m of magnetic tape to attach the acryllic glass to my window frame (I used Gauder Typ A+B magnetic tape)
• superglue
• [optional] 4x flat PETG scraps
  • 1-2x small clamps
• [optional] protective metal paint
  • a small brush to apply the paint
• handmill

Printing

I printed all parts in Prusament PETG Jet Black with a 0,4mm Revo Six Obxidian Nozzle (any 0,4mm Nozzle should do) with a layer height of 0,2mm on a Satin Sheet on my Prusa MK3S+.

The inside plate as well as the grip are printed with five perimeters, the outside plate is printed with three perimeters and 25% infill.

Important

Use the infill mode “gyroid” for all parts for the best structural integrity.

Assembly

1. Print all the parts
2. Test the fit
3. Prepare your window fitting or acryllic glass for your window
   1. mark where the adapter needs to go and drill 10 holes
      • two for the grip
      • four for mounting the adapter plates
      • four for starting/ending your milling) 
   2. inset the drilled holes with a larger drill
   3. mill the hole (use a guide) and clean the cuts
   4. fix your mounting hardware, e.g. the magnetic tape to the window and acryllic glass (take care to use the opposite tape of the one you put on the window frame for the glass or else it will not work)
   5. [optional] put the UV foil on the glass
4. mount the grip using the two M5x16 screws, two washers and two nuts
5. install the mosquito net
   1. cut the mosquito net to fit the inner plate
   2. glue the mosquito net on the inner plate with some drops of superglue
   3. cut some of the sticky gasket tape (which is part of the Bosch Cool box) to fit the inner plate
   4. attach the gasket tape on the edges of the inner adapter over the mosquito net to make sure it seals properly when screwed on
6. [optional] Enhance the mounting strength of the mosquito net
   • put some more glue near the inner corners of the inner plate on the mosquito net
   • put the flat PETG scraps in the corners, pressing them on the glue
   • clamp everything together for a more robust mount
7. mount the outside and inner plate to the glass pane
8. [optional] paint the washers and nuts on the outside with protective metal paint
9. attach the glass pane to your window
10. attach the air conditioner
11. Congratulations, you're done - enjoy the fresh breeze