I'll happily provide all the photos you wish. It's the least I can do in return for your providing the key to resolving my issues.
To answer your questions:
Yes let's move over to the a/c thread.
Yes the ductwork is ideal in length and location. I believe the Brits felt that the Yank concepts of "air in your face" and "popsicle nose" were a bit forward, and interfered with proper cigar smoking.
Yes the Northern CA climate is mild but a/c is mandatory in 2012.
Yes I have the case out of my parts car. The only complaint I have with the design is that the fan motors need to be souped up.
No, no rust issues with my "real" 420G.
Yes, rust proofing is a must. But I think a very tight painted sheet metal tray with edges turned down, bonded in (no screws) with 70s style 3M trunk & fender body putty (semi-hardening) will be fine.
Here are a couple "teaser" photos. I'll get more for you.
[You must be registered and logged in to see this link.]See you across the road.