Problem with making you're own-- DOM is expensive! Johnny joints are expensive! All that junk adds up. I looked at that idea to. You can get Rusty's long arms for like $470 or so.
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2"X.250 DOM is around $10/foot here so most of the expense is in the joints/rod ends. I would agree that long arms can be made much cheaper than $470 with the right tools., even if you used thicker material for the links.
why not use actually joints on the long arms??
here was my design i was gonna custom make
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and here are the joints i'm speaking of
http://www.partsmike.com/store/store.php?crn=238&rn=1596&action=show_detail
$50 comes w/ insert and jam nut.
here's the bushing for the axle side of the lower
http://www.ballisticfabrication.com/Ballistic-Forged-Poly-Bushing-263_p_1646.html
use a bushing for less vibes and better ride (if a DD, if not-- use another parts mike joint there)