I've had a breakthrough...
I don't know why I didn't try this before. When I turn it to 5 (all the way up) and tap the knob or hit the knob the fan starts on full speed immediately! This leads me to believe it's the blower switch. Perhaps a short somewhere. Any objections or thoughts?
New blower switch: http://www.rockauto.com/en/moreinfo....0488&jsn=10488