Is metal ductwork required on supply?
Difficult transition at wall register would be easy to frame and build with wood. This would be over 20' from the furnace, which is not "really" a furnace but an air handler with a hot water coil in it. No flame associated with it, temps below 160F. Total lenghth of transition about 18". Antique register, odd size to it.
If it is just a framed box you are wanting to build to adapt to the register, it should be fine. If you need to run 20' of this, run metal duct (round, buy at Home Depot, etc.) 6" for 100 CFM, 7" for up to 160 CFM, 8" for up to 200 CFM. Then you can make the box you are talking about.
Return ducts are commonly run as "chases" in houses, not using metal ducts, by using the framed openings behind existing walls or by using joist bays covered in flat metal turning it into a "duct".
It is preferable not to use the same as a supply, as the wood will dry out and the cold air in summer may cause mold or mildew to grow on the wood. It would probably be better to get some flat metal and fabricate a register box yourself.
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