The fan that pushes the air into the duct work is probably either about to go out, or the blades are slightly rubbing on a plastic duct. The plastic will get hot and melt a little causing that smell.
If you ever look at the blades of a box fan in your home, you will notice that they jump forward slightly when power is applied to the motor. It is common in the brushless fan design, which is what is in your heater system. It also uses air from the duct to cool the motor. Make sure that the little rubber tube on the bottom of the blower motor is not clogged with debris.
If none of this helps, reply here, and i'll look up more ideas for ya.
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Wednesday, July 18th, 2007 AT 10:44 PM