x2. i was going to build one to try to save some cash, but found that it was cheaper/easier to just buy one off the shelf. there are alot of good deals out there and im sure theres somethin you like out there
where do i start? what brands should i stay away from and what would be the cheapest route?
how much more expensive would the 5.56 or 5.45 be?
Have you done a search on this forum yet? Seems like that subject has been addressed in a number of previous threads.
IMO, start with the lower receiver, since that's the only part you have to purchase through a dealer. Then do some homework and decide what configuration you want (i.e. what do you want to do with the gun?) and whose parts you want to use, and start ordering...
As to brand of lower... don't get wrapped around the axle on that one; they pretty much ALL work, provided the holes are the right size and in the right place. Make your selection based on whatever criteria you want - who has the coolest logo, or smoothest finish, or best price. Whatever. I've built on Bushmaster, DPMS, Rock River, Stag, Superior and Olympic. Only one I wasn't happy with was the Superior (it was sold as a "cosmetic blemish" but it also had dimensional issues). You can pick up a DoubleStar or Aero Precision stripped lower from AIM for about $100, and they're close enough you can drive over and get it, which saves you shipping and FFL transfer fees. I haven't personally used either brand, but I hear good things about both.
Finally, let me address a common question about building... doing it yourself won't save you a DIME. What it will do, however, is allow you to 1) assemble the rifle over time rather than dropping a big chunk of change at once, 2) build a configuration not offered as a factory item, and 3) personally ensure the quality of the parts used in the build, and of the build process itself.
good luck!