Boy, Snakey, that's a good one...I get intermittent fogging issues with my goggles too, and mostly find that a combination of my R1 balaclava and careful, pursed-mouth breathing with a bit of an overbite works...
I would venture a guess that you're "too warm". Sounds like you have a nice area of trapped, dead air space there around your neck/face on account of all that insulation, which then allows the vapor in your "hot breath" to stay unfrozen as it is exhaled past the outer scarf layer, where it promptly hits the cold lens, gets stuck, and is frozen...the "covered in frost" part, right?
So, reduce that warm air "pocket" and let the vapor freeze before it hits the goggle, and give it less ability to stick once it gets there: pare down your neck neck/face/head insulation, use a helmet with the least amount of overhang + copious ventilation, anti-fog coatings...
Maybe switch out the balaclava for a thin liner beanie and a Buff, and loose the scarf. Again, on the helmet...an integrated helmet/goggles combo sounds like a good idea until your head overheats and the whole system backs up, preventing the convection column of hot air your body is surely creating while at speed in sub-zero temps from quickly dissipating, and leading to frosty goggles every time.
When you get to your destination and take your helmet off, is your head steaming to beat the band?
(Edit: On second thought, please do the snorkel thing. I'd start with a $40 respirator from Home Depot and some Sugru. Take pictures and post them to Trailspace. If I faced such an issue, that's surely what I'd do...)
Wow....this is great info! I never thought about that, and you are probably right as my head does get warm. The helmet has ventilation that I can turn on or off, which I do use. The next time I go out I will keep the vents open and see how that helps. When I use a balaclava that covers my mouth the goggles get fogged up too, worse even. So what I was doing was to cover my face with a loose weave scarf, which allows my breath to exit better, instead of collecting at my face....much as you have pointed out. Now that you mention it...that probably helps my neck warm up more.
I came up with the idea to use a snorkel because as I ride (or snowshoe..anything that raises my heart rate ) I start breathing in large volumes of that really cold air. I discovered this when my throat was always sore which I figure is from the extreme cold air. (It is actually very noticeable as it hurts when I breath so hard in the sub-zero temps) I was just going to use a snorkel mouthpiece with a hose attached that I will run through my jacket. I think that will stop the throat problems as it will allow the air to warm before it enters my lungs. I am working on a check-valve that will allow me to regulate it so that I exhale out one and inhale through another. I have ordered a new mask which I think will help too.
Thanks!