Just a bit of feedback on this, after this thread revive, i believe my dash wasn't cliped down correctly, and that's helped very slightly, also fresh/recirc settings change the airflow slightly too. It's also colder here now so not as much AC required and dont drive the car much, so can't give proper feedback, but it does hit my face now but thats still at max height.. either way get tesla to have a look at it to see if they can do anything.
Unsure about the vent being smaller, however i do notice the vent being slightly narrower (height wise) if u stick ur finger in the vent, it's easier to go in on the passenger side for a RHD car.