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Is that cardboard you've used to mold the impellor housing?, looks like wood strips!...
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Well, this one is commonly called "Wood cardboard"
It's 1mm thick but very soft to cut. I used a continuous strip with several half depht cuts to curve it.
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Get a bigger fan. You can probably find surplus 120mm+ fans with very high powered motors if you look hard enough. I know I've seen PDFs for 20w DC fans before.
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I've seen 2 amps 12v 120mm fans, but are expensive to buy new to tear it apart, not very cost effective.:shrug:
Maybe it's possible to buy the brushless DC motor alone...