Yes cooling requires larger duct work. Typically you would size the duct work for the cooling system and heat will work fine as well
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There is no answer to that, does the house need some demo to install the duct work or a lot? Are there beams or obstructions in the way?Even the costs of heating units vary a lot. Your best choice is to phone a few heating companies and get them to come in and give you a free estimate, takes all the guess work out of it.
The air is returning at a lower velocity, so you need a larger size duct.
1" Duct Board has an R-Value of 4.3
With duct tape I install and maintain duct work for a living if you want to seal the joints just wrap the tape around the duct. If you need to cover a hole you will need to screw a piece of metal on the duct over the hole and tape over the edges of your patch. this is the simplest and cheapest way I know to do it.
Ductwork is simply a duct system. Ducts are essential to the circulation of air, and ductwork describes a range of duct related fields, such as duct design.