Today I decided to investigate how the air gets recirculated into the AC system when it'* on Max AC. And to my surprise the only place I could find that was sucking air were the little vents that blow air on your feet. The vent openings are about 1 1/4 inches square give or take, and there are four of them. So if you add the surface area of those openings together, they roughly add up to the area of one
of the four dash vents blowing air on you. So basically the system physically can't blow more air because it can't supply enough air to meet the demand.
So I did what any annoyed car owner would do, I removed the plastic vents from the front kick area that blow(restrict the flow of) air on to your feet. For the sole purpose of improving air flow back to the blower, and it worked.
Here it is
I would say I picked up about 15% more air flow with those vents out. Next I'll pick up a new blower motor, cover and hopefully increase the air flow some more.