It's possible there has been some poor installation practices for your joins and humidifier (and AC). I had to fix some poor joins myself - Duct tape isn't for ducting though. It fails fairly quickly but you're on the right track with respect to sealing those holes up. Also it's a matter of hydraulics - the air will take the easiest route with lowest pressure drop so since your basement is closest then if your vents are open the air volume will be higher there than some distance away upstairs. So play with several vents... you may need to close your basement ones, and half/substantially close the main floor ones to force the cold upstairs. Every time I visit my old man in the summer I have to go around and fix all his vents to get equal AC and not leave some areas as frigid iceboxes.
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