OK, so it's been awhile, but I finally got some time to go back and complete one of the fans, the forward unit. I had to button everything up when we took her out about a month ago, and it was so hot that opening a vent was pretty much out of the question anyway.
Previously I had started on making a wood mount for the switches out of some mahogany I had lying around. The other night I got to fitting in the rocker switch and the small pot to control the fan speed. Since the original light switch was mounted in the plastic, I had to modify the wood to make it much thinner so the controls would mount correctly, I.E. not too deep if that makes any sense. Pictures tell the story better than words.
I very carefully drilled for holes on either side and used a short metal cutting blade in a jigsaw to cut open two sections to fit the controls through. I also used a forstner bit to open up the back by each control so the pot and rotary switch didn't sit too low.
I had to cut back the heat shrink on the rocker switch so it would fit in the square opening I made in the wood. The pot for the fan speed sits next to it.
I decided to mount the speed controller on the side of the diffuser. Originally it was mounted to base plate, but I figured it would be easier to deal with the wires from the controls to the board since they were fairly short. I used some Isolate it Sorbothane strip that I bought for controlling vibration of the AC unit to pad the bottom of the board against the plastic.
The wood panel was glued to the plastic using my favorite adhesive, 5 minute epoxy.
I went to the local hardware store and got some of the brass nipple stock that is what they use for table lamps, some brass hex nuts and a small dark brass finial that I used to hold the whole fixture up just like the old switch held it up before.
Lights on, you can see I didn't put the screen back in yet. So far it works well, no different from the last time. I still have to work on the back unit by the bath. I've got a few other projects on the trailer as well as around the house to catch up on, always something to do, but never enough time to do it all.