Before going further with brushless motor program, been researching to see if & how unit in hand can be controlled “correctly” as this AC app requires. Appears it can but not without experiencing a mucho greater learning curve than anticipated. Problem that needs getting around is... standard RC speed controllers need to “arm” themselves every time before they begin to operate a brushless motor. Attending this manually is certainly doable but also certainly undesirable. There are any numbers of ways to solve this problem---challenge is to find simplest way to automate it. At this moment, using an Arduino is most appealing path.
...Point in this research is to determine---right now---whether brushless motor direction is viable or not. If not, time to head in new direction. Have chosen to stay with brushless and sort it.
Tap = 4-40 (for screws embeded in fenders.)
Fenders attached for compression check. 1/16” compression per fender is too much---makes for difficult fit of unit into aluminum tube. (Housing's footers will remain in place until there’s no need to bench test motor further. Will cut footers off eventually.)
Sanded fenders down to 1/32” compression per. Should still be good grip (when inside tube) while allowing unit to get into tube without destroying fenders along the way.
Finishing intake stack.
Splash shield and top sections added.
Top-to-bottom measure = 18.5” Will fine tune this measure based on next fitting into wheel well. Right now plan is to position turbine blower just after bend at stack’s top. Aviation duct RN suggested may change this positioning---may be possible to move blower as far from cabin as possible… close to condenser. Idea being to manage turbine noise---as heard from inside cabin, windows closed---with every incremental move possible.
Aviation duct is ordered. Will do another fit-in-car as soon as it arrives. Will be interesting to see how that stuff compares to turns metal elbows make.
Main challenge on hand now is designing "elegant" electronic solution for motor's operation. If anyone happens to know Arduino sketch that will automatically arm and operate brushless 3-phase motor at prior shut OFF speed... say so please.