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If you're making your own heater box, the issue is not the blower motor, but rather the squirrel cage.
Finding a smaller one will lose air blower performance, in proportion.
I checked out your Robert's Ranger site. Wow, that setup is great. It couldn't be much of a tighter fit. You can't see where the interference is from the photos, but I'm sure it's a bear of a problem. I think this may be one of those "you have to be there to figure it out" situations. Good luck.
Would shaving the heater box itself help? Can't remember the details of what sticks out, but you might be able to take a 1/4 " off the back plastic and then fab some mount brackets to hold it in place...
Well, I hear you on the cold for sure...it was -25 last night here in ON and tonight promises to be colder...my Zuki is a convertible with a hard top...it took almost an hour to clear the glass today and I had to go to TO for a dentist appointment...my left foot was frozen by the time I got there...
Probably not many options to choose from by the looks of the picture...I would imagine it's the back end of the SC that's clacking against the box and there's probably no way to move that forward an inch even...
Is there plumbing or something else back there that can be altered other than going the fan route?