My ducts are probably slightly undersized too, when I look at them they just seem so small, and I find I don't have good airflow on the lower floor. One of these days I should redo it. Really I just need to redo that one trunk as the higher floor one is ok given heat rises and fact that some of the vents are also dedicated runs straight from the main plenum.
Eventually I want to setup automated dampers and a return bypass damper so I can fine tune air flow and have different programs such as if I want upstairs to be warmer it would close upstairs vents etc. It would also need to monitor air flow, plenum temp and other parameters and let air through some of the closed vents as required.