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I'm not keen on a window-mounted A/C unit. It'd be right on the front of the house and I have an HOA that would probably frown on it. (There's nothing inherently wrong or bad about them, but around here they're typically viewed as, uh, low-rent type things.) Also, the window opens horizontally so I think I'd have to have a platform. Finally, it would just look ugly on the front of my house.
For now I'm going to try to block the heat gain in through the bonus room window and see how much that helps.
In addition to blocking the heat gain (helps for all cases), have you tried setting the blower fan to run continuously (EDIT- I see you did mention that in # 36 - try with the ducts adjusted as well, shutting off some of the flow to the colder rooms)? Our (very) old A/C with the old Honeywell round, basic thermostat could be set to "ON" instead of "AUTO", and it would run continuously at a low speed, then go to the higher speed when the A/C cycled. We set that overnight, and it helped a lot.
Our new A/C, with fancy thermostat has a mode that can be set to run at low speed XX minutes out of every hour. It accounts for the A/C running, and will only add low speed circulation if it's been off a while.
Both cases helped keep our upstairs more even with the downstairs (where the thermostat was/is). It evens the temperature for the hot room to the colder rooms. I think most modern thermostats have some level of capability for this.
If you try the zone system, you might still run into the frozen coils that NW-Bound warned of. Maybe those systems detect that and adjust the airflow accordingly? I'd ask about that if you go that route.
One more option that might be acceptable in appearance - rather than putting a small window unit
in the window, have a hole cut in the wall for it. That might allow you to put it on a less noticeable area of the wall, and it looks better when the window lines aren't messed with. You might even be able to paint it or build a decorative panel around it so it is even less obvious? I've seen this done, and it is a big step up from being in the window. (edit - I see NW-Bound also suggested this for portable A/C venting - a similar option)
-ERD50