Hi Paul & others...your build gives me confidence to proceed along these lines..a few more questions.
Are you totally satisfied with cool air velocity exiting your unit?
the reason I ask, is most modern units have the fan directly behind the EV, and the old Jag "sucker" design blows cooled air out unimpeded by any obstruction
Is that polystyrene insulation?
what is the approx dimensions of your EV core?
did you say the outlet is fibreglass?...how were you able to form it up so nicely?
most EV cores are squarish, with a single fan.
I can obtain a complete assembly from a GM (large sedan) for $85, which has fan , EV, heater, ducting etc, can gut and reassemble the needed parts within a fabricated structure...the EV is about 25 x 25 x 10cm
an extra blower motor would be $20...they blow a gale and draw up to 30A start current each on full power. It would probably work fine with just one, but to look "right" really needs the 2 fans
it should be possible to obtain a more rectangular one, but they are much less common, and I would also prefer o-ring type ends
I will consult with my A/C specialist...he said he is not afraid...did you have any difficulties finding an aircon guy to gas it up...or did that yrself?