Here is a cover that I made to cover up holes in the floor when we replaced our forced air system with a hydronic system in our old house in Maine. From all appearances it looks like a working register but blends into the Fir flooring very nicely. I think we had about a dozen holes…
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Did you use a scroll saw? That is a lot of work. Nice job.
No, CNC Router and a bit of woodworking to form the basic shape and finish.
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Our HVAC company designed my retro-fit to add central heat/air to our home back in the 90’s. What a project!!! I did all the work to expose and cut holes in the floor and the sheet rock below so they could run all the lines.
In this one space, I put manufactured stringer/floor joist on 12 inch centers to span the 22 feet and not take up too much headroom in the garage. The problem is they had a flange that left about 8 inches of space between them. That meant there was no room for a typical floor vent so they put wall vent sizes 6X6 which was not ideal. There was no supplier of vent covers that withstood walking on them. So this is what we had for about 2 years.
As you can imagine, they were all caving in. This is what I made out of wood. Not fancy but they have been there for more than 25 years and have not sagged 
, but not very decorative either
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Cut four 4x8 sheets of 26 gauge galvanized. All nest with different duct patterns.
Air out the shop from all the toxic gas and then start fabricating the parts.
Cutting galvanized can be ugly business.
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Cuts on hands and fingers are sure nasty/painful from galvanized metal!
That is a lot of cutting!
That too, in this case I was thinking zinc oxide poisoning or metal fume fever.
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And have you taken a good hard look in the mirror lately? A few of us seem to feel there is something unusual going on. I know you are showing us your good side…smile and all…but:
P.S. Agreed. The fumes are toxic. I know you wear a good respirator.
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Here’s a couple of those pieces from yesterday. A roughed in the furnace of complete the install tomorrow. This is a new furnace being adopted into an old system.
I like enormous filters and the static pressure benefits they bring. My go to size is 20x25x5
Once I finish up the install post some pictures of it done.
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Time to put that duct work to work and make a fume hood for the XR? 
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I did finish this system up.
It’s a two-stage high efficient gas furnace paired with a outdoor heat pump.
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You’re an artist, TW!
Fine work!
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Nice organized clean install…
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Gonna need dampers, the air flow will be too good off that plenum lol
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Oh my…you were right there on the boundary line!!!
You should have texted me and I would have brought some Earl Grey!
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So, what are you planning? Your own border crossing with Tolls but no papers needed? 
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An American bringing an Englishman from Canada tea…
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