Met with my contractor yesterday, and looks like we will start framing in two weeks. I've got most of the details planned out, but HVAC continues to give me anxiety.
I think I have decided to run the supply over the top of the ceiling and then drop down into a soffit muffler:

I will keep the dead vent next to the HVAC unit and vent it to the unfinished basement. This brings up a few questions:
1) Is one supply enough?
2) What size fan for the return would be adequate?
3) Should I add a return for the projector which dumps into the dead vent with a second inline fan -- as seen in
235 build? I had not planned on having a sealed hush box, so I could just make sure the box has some ventilation in the back as an alternative. I guess I could also seal it up and hook it up to the return, but I don't want to get into anything too complicated (already feel I'm in over my head!).