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Gidday Ben, this is not to criticize but just to query. I think the direct drive system will not work with any of the front Fan grill or sensor set up?
I loaded a file here so you could clearly see what I mean https://www.thingiverse.com/thing:3509086 am I missing something? Cheers Jace

I guess the easist option is to revert back to your original concept and then the question is which is the better set up?

Direct Drive - IR Sensor & Hot end Test Model