AC retrofit on 72 Overlander works better with a flat ceiling

[zephyr9900]

I purchased the 72 Overlander in 2012 and immediately installed a new Dometic Penguin Air Conditioner similar to a video I found by Classic Rides. But the problem I have is that the ceiling is not flat in an Airstream but the Dometic AC unit is made for a flat ceiling. This causes the control knobs to not engage correctly and sometimes they fall out or not work.

To solve the problem I made a flat ceiling adapter.

Before installing the adapter the AC mounting frame around the opening was fabricated to match the ceiling shown in the attached PDF "AC Roof Mount Frame"

Next I made a ceiling adapter that transitions the curve ceiling to a flat ceiling. The most difficult part to make are the cured trusses made from 1 X 2 pine boards.

The flat area of the adapter is made from 1/4" hardboard.

I have my own machine shop so made the trusses and mounting frame curved parts on a CNC milling machine. These can be made pretty fast once the machine is setup. (If you think I might be able to help you please contact me.)

Attached are some photos and a drawing of the curved truss.

John