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I am thinking about deleting the fresh air vent due to the roll cage. anyone had issues with the heater sucking air from in the cabin without a fresh air vent?
That's how a Vintage Air unit does it. It just recirculates the inside air for both the A/C and heat. It uses the A/C for defrost rather than outside air. Your defrost won't work well without outside air.
Tried that once back when I lived in Kansas. Though it would make the heater better. Bad idea. Removing (or displacing) the humidity is a must. Fresh air is best, A/C to de-humidify the air also works just not as well. Weird having to run the A/C in the middle of winter so you can see out the windows.
For fresh air you have the driver side vent and most EBs have a few unintended fresh air vents. If you want to test it for your self just leave the duct off and tape up the hole. If it doesn't work out for you put the duct back in.
I would also fear it would burn up the fan motor? I covered my duct up once n tried the fan and wasn't blowing hardly at all n the fan motor got real hot!
That is basically what I tried. I removed the duct from the inner fender to the heater (to suck air from the cabin) and covered the inlet under the hood (to seal out the fresh air inlet).
Easy to try, results are predictable. Colder it gets the worse the humidity build up gets. First snow and it is nearly undrivable.
This is why I have been dithering on the whole aftermarket Vintage Air-type AC install. You loose fresh air for the heater. Also without the fresh air intake you will loose the "pull for heat (fresh air)" function. In moderate weather you pull that center knob out and push the right hand knob all the way in, and you get cool fresh air. Some folks never figure that one out, delete the fresh air box, and as said above, they got no defrost, or cool fresh air.
I have not had the windshield fogging up problem for more than a min. Turn the heat and/or the fan up on defrost and the fog goes away. Doesn't mean it will work everyplace but it does work for me here in TX and in CA.