OK so back on topic here. I was under the hood this weekend and I think I have conceptualized a solution to the hot air when using normal vent only. Basically, the firewall all the way from the wiper motor to the brake master cylinder has 2 zones: the area level with and below the heater water hoses are (mildly) insulated, while every bit of firewall above it all the way to the cowl is 100% uninsulated. So unless someone beats me to this (I won't cry foul if so) I will be making a metal heat shield that can be attached at the cowl and hang down to cover this area. Between the firewall and heat shield, I will probably insert some type of high-heat loose-fill insulation, adhearing it to the shield so that it will stay in place. We'll see how that does. But yeah, the heat from the engine bay could very well be part of the problem we have in my car with excessive temps inside and insufficient AC cooling. So depending on when I can fabricate something, I'll report back.