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I have the same Hot Dawg furnace and its WAY too loud. Three friends have Reznors and they are a fraction of the noise.

In your first pic the wire looks cooked too if you look back a few inches. I think you might need to look into why the wire burned off instead of just attaching it.

What is the ceiling covered with? You said R30 and no drywall yet if I read correctly. Are you losing heat by not being sealed up?

Where I live electricity is .07/kw/hr so that heater would cost $0.35/hr to run. Please let me know if I'm figuring it wrong as I'm looking into the same issue.

Hmmm, I pay $1,100 per year to heat and cool a 2,800 square foot house and a 1,000 square foot garage in the Midwest. I'm not sure $10 k in foam could ever pay for itself. Would it save half of the current energy costs?

The real key to keeping it quiet in the room above is to change the mounting system. It needs to be isolated from the ceiling/floor somehow.

I don't see any place to look for an error light unless I need to take the control panel off first. I use an old style mechanical thermostat and am usually going up from around 50 or 55 degrees to the high 60s. I'm starting to think maybe the flame sensor is bad as the first cycle is usually for...