Did you get everything straightened out OP?
Yeh, thank you. I'm more or less resigned to the idea of lever-less returns - but now I'm wondering why do supply registers have levers if stopping airflow is bad? You're also increasing the supply duct pressure then too...right?
In theory, if I have a leaky house (which I do), closing a room's supply would stop airflow, and the blower would still suck air from the room and suck outside air through the cracks and crevices in the walls, windows and ceiling of that room. Then you have cold, unconditioned air hitting the heat exchanger. Right?
Anywho, I guess there are efficiency issues everywhere, you just need to manage them as best you can depending on your setup. My house has no returns at all (blower is just sucking air from the basement), so anything I do is going to be better than what I currently have.