Hey Mudball:
Manufactured duct work is 8" thick and made in widths from 8" to 48". Do you know what source of heat and air conditioning you will be using. It can make a difference.
There is a systme called Unico (there is another brand also) which uses 8"X8" square fiberglass for a trunk line and the branches are flex hose the size of a vacum cleaner hose. The outlets look very much like a porcelain rosette light fixture. It can be used with any outdoor heat pump of the same rating. You will not feel the air moving unless you stand right under an outlet but the high velocity fan will force the air circulation throughout the house. I know several people who have this kind of systme and they swear by it. I don't have a web site for you but I do still have a brochure.
Glenn
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