I have never seen a return hose used for the return air, but 2" seems big enough. More than I have now with no return tube.
As for the fan the only realy difference between A/C and D/C is the wiring config and the noise (DC is quieter).
I have a 32 cfm blower, but I have seen (on here) that less works fine for tower cooling...I just wanted to be safe and that is what Psychodad used.
Otherwise...Cubby's link holds the rest.
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