Just read the whole thread, you sure type a lot of words paul ;-)
I'm basically doing the same thing myself, except I'm working with a van with a roof covered in solar panels. 400w of panels cost about $1000 on ebay. So far I have a 30A MPPT controller, but only a single 40w panel for testing purposes.
For the headlights, why not add the voltage regulator just before the headlights? That way you can run a single battery but still have 14.5 to the headlights at all times.
As to PWM vs resistor fan controller, OEM's have been using PWM since the late 80's but you have to buy a model with Climate Control to get it. I just bought a 10A unit to experiment with. It will run my DRL's, but I'll try it on the fan first. I plan on adapting the potentiometer to take place of the OEM switch. The adjustable preset speeds idea is a good one though, but I figure there'll always be a point where the desired speed is in between two settings.
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