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Chris, I applaud your enthusiasm!
Although I have yet to build a double of any kind, I do have some double rifles and have given a build a lot of thought myself.
One thing I may have missed in your posts is, what caliber/performance range cartridge are you wishing for and what do you intend to use your rifle for?
The reason I ask is that if you want to go big, you may want to start out with a 12 or 10ga with shortened barrels and see how it works with bullets, sabots or round balls. Some other members here have been quite successful in getting a smoothbore to shoot well and it could be just the experience you need as far as setting up a regulation jig and getting the barrels to shoot together.
Then, if that ends up not being your cup of tea, just cut the barrels back for a monoblock and go for the whole rebarrel job.

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Actually my build buddy has a 12 gauge exposed hammer double barrel cheapo'1920's "Get off my porch" granny gun (as we call it), we've been thinking about getting our hands dirty with regulation using it. Its action is probably not strong enough to support a rebarrel job (cheap Sears special I think, the brand was only made for less than 10 years if memory serves I'll have the info today; he's down the hill in Sacramento defending the nation's toast).

As far as caliber goes for our first build? We're not sure. I'd like to stick to a classic round, something strong enough for pretty much all North American game but not extravagantly large. .375H&H, 9.3x73R, of maybe non-spitzer like a .400 jeffrey or .450 Nitro would be right up my alley but he wants to go with a wildcat (something I'm against for a first build of this type). I've been thinking about that a lot, and I'm open to any advice you guys have

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