A friend has a house with two gas furnaces and AC. The downstairs one is OK, the upstairs which is based in the attic is very marginal at best. The biggest problem is that there is not enough air flow. It's really only a problem in AC season, when it takes a very long time to cool. It has to run most of the day just to keep it at
It would appear that is due to a number of factors. The way they did the ducting is far from optimal. Right off the furnace the duct makes two 90deg turns, then feeds down a long duct off of which come flex hoses that feed 5 bedrooms and two baths. The furnace is located close to one long side of the house. Three of those supply hoses have to go up close to the peak of the roof, going across to the other side of the house. They did that to avoid going straight across the attic floor, leaving space for walk-in accessibility, which is good, but it comes at a cost. The return ducting is good. The AC itself appears to be working, the air coming out is 15 deg cooler than going in, closer to 20 deg right at the unit.
So, looking at this, I can see some possible improvements. Obviously doing something with the ducting would be beneficial. But I also looked at the blower and right now it's a 1050 RPM 1/3 hp. I'm thinking part of the solution could be to go to a 1650 RPM, 1/2 hp, which should be a drop in replacement. I know it's not a total solution, but even if the ducting stuff is straigtened out, given the length of the runs, etc, I think having the more powerful blower would still be part of the solution. Being that the blower motor is easy and cheap to do, I wonder if it makes sense to just try it and see how much it helps?