Pictures will help; as for wide "flat" hard plastic, that's exactly what they use; looks like this:It's more likely that refinements have to be made to the ductwork and possibly the blower fan, but the compressor and radiator seem to be up to the job. The claim is that the A/C performance was about what they expected (leaving room for some improvements), heat was comparable to other cars, and defrost was really good.
The big problem is distributing cool (or hot) air where it needs to be, particularly in the rear seat. There just plain isn't room to run separate ducts all the way from the engine compartment to the rear passenger compartment, unless they are very wide and shallow -- and I have no idea how well that would work. Obviously they're getting some a/c back there, and about what they expected (however good or bad that is) overall.
EM's clearly given this a lot of thought and is working on it, but at least as far as A/C is concerned, there's some distance to the goal. But since there are no required standards, they may just reach a point and call it "good enough." Don't know that that's true -- we just don't have enough information to work with.
And they can run it through the seat
And usually over the "Hump", but since the Elio doesn't have a hump, you'd use the right "door" area
Below is from a BMW
It's all better than the first idea they came up with.
They needed something sort of simple, so they used this:
But that was in a 4 door, so they had to come up with the one they have now.
