Interesting thread, Kelton - goes to show engineering in reverse. That Sentria intake cover is a joke and no wonder the meltdown occurred. How was it even supposed to blow anything with no intake? Safety laws are likely for this blunder- got to make sure someones hair will not get sucked in when they lay in front of the Kirby...
Even the early intakes/crystalators are too restrictive to use the machine as a good blower. I tried it on my Tradition long ago and the leaves on the patio barely moved. I added a sawed-off crystalator (was broken anyway) and the leaves took flight - it was amazing in difference. I only pity low flying birds that get too close...
YOu would be better off using the rug nozzle as the intake and even on low speed you would get some usable blowing action.
What is happening here is air friction (through compression) is causing excess heat in the fan chamber. The fan gets so hot that the plastic begins to melt and 'grow' through centrifugal force. This is why the blades bent also. (Metal fans are much more tolerant.)
There is just just enough air coming in through that restrictive snout to keep the fan chamber full of air but does not let the air come out fast enough to keep fan chamber air temps down. It heats up fast. Same goes from using the pool toy inflater tool. I think the instructions on later models state to limit use to a few minutes with that attachment.
As a test, when using the hose, you can restrict the air a lot for 20-30 seconds and when released, you can feel the blast of superheated air coming out of the bag.
It might be better off to have a full intake restriction when the fan chamber actually enters into a vacuum to have less air to try to compress...
As for problems using only the hose a lot, I would not worry a bit. I have done those tests many times through actual use of my Tradition in regular use. Four times a year it gets about 4-5 hours of hose use with little shut down time as I dust everything with the dusting brushes. It has a white plastic fan and it still runs great. It does get restricted a bit when in use, but for very short times.
Now if you drop the hose and it sucks on to something and you leave it that way for a while (like a few minutes or more), then you may have problems.
Ever notice that bicycle tire pump hoses heat up at the bends after you have been using it? Yep, air friction. It is why air compressors have cooling fans on them as well.
Kirby could learn a lot from a bike pump...