The Passenger side ( LHD) blower motor has a noise that sounds like the insulation has come loose and is getting hit once per revolution ( like the card in bicycle wheel trick we did as a kid). I've research this online and here in the forum, and have found many helpful posts.

I attempted the repair today, but all of the tricks I used have been unsuccessful. I can see the blower oscillate slightly when running ( could be dirt I am seeing), so it may be that the bearing is going bad, or the wheel has gone out of balance. I tried the "Pick" method, then sticky tape, then vacuum. I used a boroscope with a mirror, but could see no offending material to remove. It's possible a small piece has gotten through the slots on the fan, and is lodged between the fan and the housing. It that is the case, finding it may be very difficult. The insulation on the Recirc door has only lost about a 1" x 1'2" piece of foam, with ragged edges, so assume it may have crumbled over time.

I think the effort to replace the motor is large, so unless there are other thoughts/ideas that I might try, I may just button it up and wait until it fails and replace it. Please let me know your thoughts. Working hard to bring this baby back to life!