I thinking about replacing the stock air control box
with an aftermarket  unit that also provides air
conditioning, instead of doing a simple evaporator add
on to the existing system.

One advantage of replacing the entire air control box
is that you would be able to use the a/c to dehumidfy
warmed air that is going to the defroster...

Aftermarket units are sold for the classic car and hot
rod market. They are designed to be fully concealed up
and under the dashboar, and some are available in a
variety of sizes, and with heat, a/c, and fresh air.

For examples see the heating/a/c evaporator units at:
http://www.vintageair.com/vintage.htm
http://www.hotrodair.com/products.cfm
http://www.nostalgicairparts.com/evaporators.html

My first question is if anyone knows the approximate
dimensions of the stock Vanagon air control (heater)
box (under the dashboard)?

Thanks

Tom F.

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