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Great question, I have done a few mods myself. I do not think you want to change to bring air from under the kitchen cabinets. The return air grill and thermostat are mutually inclusive. The furnace is just loud when it is on. So my feeling was if I can get the thing to make the air temperature stabilize faster in the Monty, the less time it will be running. On of the first things I did was to take the furnace out and seal beneath it. I did not take any pictures of the area, but I can tell you it was a poor quality installation. Pretty much Keystone people take a circular saw and cut an opening into the duct beneath the floor. My hole in the floor and the furnace opening from Suburban were almost two inches off from each other. The cheap gasket Keystone came up with did not even make a seal between furnace and floor so therefore a lot of air was leaking out.
Keystone only wraps a few single plys of aluminum foil tape to seal gap between floor and inside surfaces of ducting. The tape wasn't even doing its job. So I ran a few screws to tighten the metal duct up to the bottom of floor, and then put three layers of a super foil duct tape around opening. Next was to make a new gasket which I did by buying some foil backed fiberglass insulation and taping it down over the opening. Now the furnace blows all the air down in the the duct and not out under the floor or in the converter compartment. I also tape all the removable 4 inch duct takeoff covers tight which are not used on furnace.
One area of noise you cannot stop unless you change the motor is the sound and vibration the furnace makes when on. The motor/squirrel cage runs very fast and has a high pitch. It also vibrates the floor in the whole trailer. If Suburban could use a slower motor it would help with the sounds and vibrations.
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