Todd,
You will find that both you and your questions will be welcomed here. I know that I have learned a lot for the posts I have read.
You first have to decide what you want to use the gun for. The intended use will drive decisions regarding size, shape, style. You can't start off with the notion that you want a light hunting rifle and then, half way through the project, decide that a heavy target rifle is a better objective.
A lot of your initial questions regarding the constriuction process can be answered in a number of how-to books. The Gunsmith of Grenville County by Alexander and Recreating the American Longrifle by Alexander, Buchele and Shumway are the two that I found most helpful. I don't own Chuck Dixon's book but I have been told it is very good.
There is a tools tutorial here which will help you get started on the array of tools you will need. You will learn that you workmanship will be limited by your tools so spend wisely.
So, now with the questions.........shoot!
Best Regards,
John Cholin