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How Much AC

In taking on this AC project Ihave to admit that this one is pushing my limits of keeping things balanced to run optimally and efficiently.

The efficient part is not that cumbersom but engineering the system to actually do what it is suposed to do is another. I have decided on the SpacePak mini duct system like I mentioned before, to eliminate the need for large box in corner units on the first floor. However, in my design of this system I am creating box-ins in other areas, mainly one bedroom and part of my bathroom. I'm not sure this is worth it but I have to get these delivery runs down to the first floor where the family needs to be comfortable. I have opted for the largest air handler that is produce by spacepak. This airhandler matched with a 4 ton condenser unit on the outside should provide adequate cooling for this large house. I am a bit worried about the return air situation though. Since the airhandler is in the attic this should be simple right? Well the attic is a finished attic, this produces the problem. I have roughly a 24" oval that needs to 48" minimum out from the airhandler.... More stuff to think about. Good thing I didn't become an Engineere.