12" return is almost definitely too large for the basement. I have a 6" return in my basement, and I have actually found it to draw ~200-240 cfm (using a barometer) -- plenty in my case with just a few supply outlets. In your case, I have no way of knowing for sure, but I assume it's piped directly (or near) to the inlet of the furnace blower compartment, in which case there is a lot of pressure and it's sucking in a lot of air and making the basement quite negative (not a good thing). So your basement return in that state may have been drawing close to, if not more than, half of the return air the entire system requires. Is the basement floorplan open to the rest of the home or closed off? If typically closed off, I wouldn't be surprised if the basement door had a tendency to close itself when the system was operating. I suppose putting cardboard over half of the grille is one way to reduce its intake capacity. Your older furnace does not (presumably) have a variable speed blower that will vary its RPM in order to maintain a specific CFM setting. That means that while you are noticing more airflow from the rest of the returns throughout the home, in totality your system is receiving less airflow -- no, not a good thing considering your ductwork is likely undersized to begin with. You have decreased its return capacity. To get the SAME (total) airflow from the rest of the returns throughout the home that were not previously drawing as much air generally requires the system to operate at an increased static; with older PSC type blower motors (non variable-speed), this results in decreased airflow. Hence variable speed motors are often termed "constant CFM" as they can adjust (increase) their speed to maintain a constant airflow (cfm) when subjected to as much as 0.8-1.0" of external static pressure (vs. conventional blowers max. of 0.5", which many duct systems are nowhere close to achieving despite it being the standard "design" figure). You can think of the ESP number as a measure of resistance to airflow, in a sense. The fact that you say the (supply?) ductwork is now much warmer is both concerning and telling. It is unwise for me to say much more than that as I am not there to evaluate your system design and give an accurate assessment of the ductwork design/layout, etc. But it suffices to say, with the info you've provided us, your return ductwork is now more restrictive, which would exacerbate any existing airflow issues. You do say it met the set point without tripping the high limit. Please let us know how the system performs as it gets colder out and the system runs more often in its present state. I would like to ask what made you consider replacing the systems (and proceeding to get 8 proposals) in the first place? Are there functional problems with the existing equipment (besides most likely being oversized) or other comfort issues? By now we have at least established that it is likely the existing equipment is a bit oversized and the existing ductwork is marginal -- but that is (unfortunately) exceedingly common on most residential construction. Are you after more efficiency, better comfort, both? It helps us to help you when we know more about your current system's performance. Lastly, I would not factor online reviews into your decision too much. An air conditioner or furnace is not like most appliances (such as a refrigerator) in that the installation practices and quality can make or break even the best equipment selection. There is a good chance that many (but not all) of the negative reviews you read were due to installation errors. This post was edited by ryanhughes on Fri, Nov 22, 13 at 9:51

We are in Leesburg and are working with Kitchen Intuition in Warrenton. It's a bit of a hike, but Andrea Rexrode is the owner/designer and is fantastic! I went out to her office once and haven't had to go back again (she's so creative and works well via email if you don't want to go out their too often). I should also mention that I worked with another kitchen designer for about 6 months and was near tears. My builder recommended I contact Andrea and within 2 weeks we were done with the house. She's fantastic (and, we have the same name, so I like her even more!) ha! I'm recommending her bc she actually works with custom cabinet makers and carries a few brands. She's been able to do our entire house for a very reasonable price using a variety of them (high end kitchen with some custom items, but maybe less expensive items for mudroom, laundry, etc). She's definitely worth a call - 540-347-3871 (and, I'm glad to send you what she did for us as well)

Have you talked to Heartwood Design? They are in Afton, not too far from you. We are in Lynchburg and they readily traveled to us. I know they have completed work in the No. Va/MD/Washingon, DC areas. I cannot recommend them highly enough - craftsmanship, expertise in design, worked with me on my budget and my dream. After a year of using my kitchen, I would not change a thing and the quality of our cabinets will last a lifetime. Good luck with your project! Also, feel free to email me if you have specific questions. Here is a link that might be useful: Heartwood Design

Decornovice: We are in NJ and are going to use www.heardwoodworking.com My architect recommended him for top quality 100% custom. We met with Russell the owner and his price is the same as a local shop quoted me for omega/dynasty. Russell's cabinets include install and there is no tax b/c he installs so it's a capital improvement. He is very passionate about his cabinets which he calls furniture. Love that! You may also remember Smarge- she used a custom guy for built-ins and her bath. If I remember right, she loved him and wished she used him for the kitchen (I have no idea about prices...) From Smarge in NJ: Our cabinet maker, as I'm sure you've read in other threads, is the #1 favorite sub our contractor used and we have hired him directly for many other projects which we love. His name is Rich of Siena Woodworks in Rockaway NJ (973) 495-2000. He is talented, intelligent, calm (valuable on a busy job site!), and very good at planning details in advance. If I knew then what I know now, he absolutely would have done my kitchen (although I am still happy having worked with my KD bc I had no clue when I started planning the kitchen. I used Jeff Kennedy who works out of The Sawhorse in Millburn. I just would have preferred cabinets by Rich instead of the Kountry Kraft I bought.)