Hi Richard,
Back in 1966, since I could breathe heavier than my defroster could blow, I decided to improve this part of my 2-year old Healey. Dismounting the Smiths blower, I split the case to install its squirrel cage onto a contemporary junkyard-scavenged Oldsmobile Star Fire heater motor. Closing up the case and installing, the much-increased volume of air has produced a slight defroster whistle but has provided good air volume to date.
Should you not be concerned about original appearance and since the heater blower is installed in a relatively obscure location, you may also want to consider replacing the Smiths unit with a 3" boat bilge blower that will provide considerably more air volume and fit nicely into your heater ducts. I have installed a 4” bilge blower, with variable control, into my fresh air duct behind the driver foot well in the engine compartment and found the resulting fresh air flow satisfying.
Also, as I had mentioned with my fresh air blower, consider installing a Pulse Width Modulation (PDM) motor speed control. This variable speed motor controller can be mounted in an accessible, but obscure, space under the dash between the original ON/OFF switch and blower to give you air flow choices. Installed in this way, the motor will be activated by the dash on/off switch and speed controlled by the PDM from under the dash.
One last suggestion while the fender is off, improve the blower’s ground connection by drilling the original screw hole and welding a nut to the frame to accept a grounding bolt.
All the best,
Ray (64BJ8P1)